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[0001] This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/083,073 filed Jul. 23, 2008, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] The disclosed device relates to instruments employed in dental surgery. More particularly, it relates to a dental retractor which includes a reflective surface at a distal end adjacent to the surgery site in the patient's mouth. Additionally, it includes means for adjusting the proximate end for ergonomic positioning for the user.
BACKGROUND OF THE INVENTION
[0003] Dental surgery, especially in the rear portions of the mouth, is conducted in the narrow confines of that mouth with dental instruments which must be employed with great precision by the medical professional using them. As a consequence, it has become conventional during such procedures to employ retractors to expand the area employable to manipulate instruments. Further, such retractors are also deployed during surgeries to allow the dental surgeon a better view of the intended surgery site.
[0004] Consequently, the surgeon, and frequently the assistant to the surgeon, manipulate a number of surgical instruments within the mouth of the patient concurrently, much to the chagrin of the patient. In procedures where gums or teeth are being treated, the use of a dental retractor to move the cheeks out of the way to provide more space for other instruments is common. The retractors are engaged as a pointed distal end with the teeth or gums and then employed to pry or bias the cheek of the patient out of the way. The cheek of the patient is a muscular portion of the face and the skin is generally tight anyway, so it takes a good deal of force to move the cheek and lips and tongue out of the way, and maintain them in this position for the duration of the surgery. This can have a fatiguing effect on the surgeon or assistant assigned the task of imparting that force and maintaining it using their fingers, hand and arm. It is thus important that the proximate end of the retractor is comfortable to hold over long surgeries, and also of a shape that is ergonomic so as not to cause injury or fatigue to the person tasked with holding it for the surgeon.
[0005] As noted, the field can become very crowded due to the inherent limit of space provided by the area of the mouth. Numerous instruments such as drills, curing lights, mirrors, gum retractors, sutures, and other devices may be required at any given time during a surgery. Consequently, it would be an advantage if surgical instruments might be combined to reduce the number of instruments having to occupy the mouth at any given time. Frequently, one such instrument is a mirror employed by the surgeon to view a side edge or back side of a tooth or gum portion of the mouth being worked upon.
[0006] As such, there exists an unmet need for a device and system to combine a retractor with a reflective surface to eliminate the need for two separate instruments in the patient's mouth. Such a system should provide for a mirrored surface at the distal end of the retractor which will accommodate the surgeon's eyesight. Additionally, such a device should more easily image the area of the mouth which the surgeon desires to view during a procedure through the provision of an angle adjustment of the mirror and image magnification if needed. Still further, such a device and system should provide optionally for additional illumination if needed especially in combination with the mirror for imaging.
[0007] An additional improvement in such a device may also include a means for suction combined with the retractor and mirrored surface at the distal end of the retractor. Such a combination will not only place the mirrored surface adjacent to the patient's teeth, it will maintain the level of liquid in the mouth at the site at a level below that of the mirror being employed to concurrently view the work being performed by the surgeon.
[0008] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings nor the steps outlined in the specification. The invention is capable of other embodiments and of being practiced and carried out in various ways as those skilled in the art will readily ascertain from reading this application. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0009] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing other methods and systems for carrying out the several purposes of the present invention of a device which is a significant improvement to dental retraction instruments. It is important, therefore, that the claims be regarded as including such equivalent construction insofar as they do not depart from the spirit and scope of the present invention.
OBJECTS OF THE INVENTION
[0010] An object of this invention is the provision of a dental retractor which has a reflective surface employable at a distal end.
[0011] An additional object of this invention is the provision of such a retractor which may be assembled from multiple components with ease to allow adjustment of the optics of the imaging mirror to the user's preference.
[0012] Yet another object of this invention is to provide a dental retraction device which is ergonomic in application and use to spare the user discomfort and even injury over long term use.
[0013] Yet another object of this invention is the provision of such a retractor with a reflective distal end in a kit form wherein the optics or the reflective surface may be adjusted as needed.
[0014] Another object of this invention is to provide such a retractor which optionally may provide a light source while in the mouth focused on the area being imaged to enhance the reflection in the reflective surface.
[0015] Yet another object of this invention would be to provide a reflective surface for a dental retractor which will allow retrofitting of the millions of retractors currently employed and provide customizable imaging through adhesive backed mirrored surfaces which may be adhered with different viewing-angle and imaging qualities.
[0016] These together with other objects and advantages which will become subsequently apparent reside in the details of the construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like parts throughout.
SUMMARY OF THE INVENTION
[0017] The device herein and method of forming the device herein from engageable components, provides a novel and useful dental retractor which concurrently provides a mirror or optically reflective surface. Consequently, it may take the place of two instruments which must currently occupy the crowded field in an oral surgery or during a cosmetic or other procedure in the mouth of a patient.
[0018] While depicted as a curvilinear generally planar retractor, the device capable of other shapes and consequently the drawings should not limit the scope of the claims in any fashion since those skilled in the art, reading this disclosure, will surely discern other modes of the device using the principles herein. All such modes of the device employing a different shape to the elongated retractor as would occur to those skilled in the art are anticipated as well as any employment of another engageable reflective surface.
[0019] As depicted in the figures of the drawings the device features an elongated member having a pointed distal end adapted for engagement between teeth or teeth and gums. With the distal end so engaged, the proximate end may be biased or forced against the edge of the mouth of the patient to move the cheek and/or the tongue away from the field of view of the surgeon of the operative site and thereby improve and enlarge the field of view during surgery.
[0020] All modes of the device employ a reflective surface which is engaged at the distal end of the retractor adjacent to the pointed or engagement edge. Thereby positioned, a reflective surface will be adapted to reflect the area of the mouth on which the surgeon is operating.
[0021] The reflective surface may be permanently engaged at the distal end of the retractor for new instruments. Or, in a particularly preferred mode of the device, a reflective surface may be temporarily engaged to the retractor thereby providing a reflective means which includes means to adapt the optical characteristics of the reflected image to the work at hand. If permanently engaged, the reflective surface may be adapted to reflect an image in a one to one reflection, or may be adapted to enlarge the image reflected or provide a wide angle view of the area reflected. The shape and optical characteristics of the mirrored surface, and angle of engagement of the surface to that of the retractor will determine the ultimate nature of the refection viewed.
[0022] If provided in a removably engageable mode, the reflective surface employed for each individual surgery may be adapted to provide customized reflective optics for the job at hand. Using adhesive or other means of temporary engagement to the distal end, a reflective surface may be engaged that is variable for its reflective properties. Such properties may include angle, magnification properties, wide angle properties, or might be a split image with two angles reflecting two portions of the area adjacent to the distal end of the retractor. In this removably engageable mode, the device in a particularly preferred mode would be provided as surfaces which may be purchased from catalogs or online sites which provide the desired reflective property of the surgeon, or in an especially preferred mode in kits of engageable reflective surfaces. Such kits would be provided with a plurality of different reflective surfaces with each being engageable to the distal end of the retractor surface. Members of the kit would include individual reflective surfaces each having a different optical reflective characteristic and may also include members each having one of a plurality of angles of engagement or the reflective surface relative to the surface of the retractor to which it is engaged. The user would choose the appropriate type of reflective surface for their individual needs and engage it thereby customizing the reflected image for the user such as the surgeon.
[0023] With the ever smaller illumination means, and safe low voltage provided by modern LED's, the device in one mode may provide illumination directed at the area of the mouth to be reflected, to better provide the user with a reflection in the reflective surface that may be seen in an otherwise dark mouth. This can be done by directing the light onto the reflective surface toward the site being reflected, or toward the site being reflected directly or in a combination thereof.
[0024] In another particularly preferred mode of the device featuring additional utility, the proximate end of the retractor held by the user or an assistant, is formed in a shape, and at an orientation to the user's hand, which makes it more ergonomic and comfortable to employ over long periods of time. Currently, this means for ergonomic adjustment of the proximate end is provided by a pivot centrally located between the distal and proximate ends which allows the user to rotate the grip on the proximate end to a comfortable orientation.
[0025] Still further, a means for suction of liquid collecting in the mouth adjacent to the site of the surgery and distal end of the retractor may be provided in another preferred mode of the device. Such a liquid collection would employ a conduit on the retractor or through the body of the retractor which communicates with an aperture at the distal end of the retractor. The aperture would have a position on the retractor such that when the retractor is in the as-used position, engaged with the patient's mouth at its distal end, the aperture would be lower than the reflective surface in the mouth. Since fluid seeks its own level, and the aperture for collection is lower than the reflective surface, suction engaged to the conduit will serve to maintain fluid in the mouth, below the level of the mirrored surface and thereby maintain it in a viewable manner for the surgeon.
[0026] The device may be provided with one or all of the components of the reflective surface, illumination means, pivot, and means for suction of fluids from the mouth, depending on how much of an increase in utility is desired. However, each addition in combination with the reflective surface will in itself provide a great improvement on available dental retractors.
[0027] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing description and following detailed description are considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a perspective view of a the device with the reflective surface positioned at a distal end on a rear surface.
[0029] FIG. 1 a depicts the rear surface of the device of FIG. 1 showing the reflective surface and optional illumination means and suction components.
[0030] FIG. 2 depicts the retractor device of FIG. 1 with an addition of a pivot as a means to ergonomically adjust the position of the proximate end and having the reflective surface on the front surface of the distal end.
[0031] FIG. 3 depicts the device with the proximate end rotated around the axis of the pivot to adjust the proximate end ergonomically.
[0032] FIG. 4 shows the reflective surface in a removably engageable mirror.
[0033] FIG. 5 depicts a side view of the removably engageable mirror showing a peel and stick adhesive back.
[0034] FIG. 6 depicts the reflective surface having a rear side which angles the surface at a different angle than the planar surface of the retractor.
[0035] FIG. 7 shows another means for removable engagement in the form of a bayonet type mount on the back surface of the mirror and a receiving cavity on the distal end of the retractor.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Referring now to the drawings in FIGS. 1-7 , wherein similar parts are identified by like reference numerals, there is seen in FIG. 1 a perspective view of the device 10 as would be provided with a dental retractor 14 body. As shown in FIG. 1 a , an engaged reflective surface 12 is positioned at a distal end 11 of the dental retractor 14 in between stiffening sidewalls 13 . The distal end 11 is somewhat pointed to allow engagement between teeth or gums or other areas of the mouth and allow the user a point from which to apply force with the proximate end 16 to move the cheek and lips out of the way during a surgery.
[0037] At the proximate end 16 is formed a curved portion 18 adapted for the engagement of the fingers of the user during employment of the retractor 14 in a surgery. In a first preferred mode of the device, shown in FIGS. 1 and 1 a, during a surgery the device 10 is placed in an as-used position by positioning the distal end 11 at the proper position in the mouth to retract the cheek, gums, or tongue as needed. Subsequently, the proximate end 16 biased or forced by the hand of the user on the curved portion 18 allowing the user to move the cheek, tongue, or other portion of the mouth to the desired position. The reflective surface 12 is positioned to provide the surgeon a reflective view of the image of the portion of the mouth adjacent to the distal end 11 .
[0038] FIG. 2 depicts an especially preferred mode of the device 10 wherein the retractor 14 has an optional pivot 20 centrally located between the distal end 11 and proximate end 16 . The pivot 20 allows the user to rotate the proximate end 16 for comfort and ergonomic concerns of the hand while in use as the retractor 14 may be required to be placed in awkward positions relative to the user's hand position. The pivot 20 operates as a means to ergonomically position the proximate end 16 by allowing the user to first properly position and angle the reflective surface 12 to show a view of the mouth desired, and then, pivot the proximate end 16 to a comfortable position for their fingers and hand which grip the proximate end 16 at the curved portion 18 . This can be seen as an example in FIG. 3 which depicts the device 10 wherein the proximate end 16 has been rotated around the axis of the pivot 20 to adjust the proximate end ergonomically. This is especially preferred to aid dental assistants and surgeons in avoiding cramping and discomfort over a long time period frequently required for a surgery.
[0039] FIGS. 4-7 show modes of the reflective surface 12 configured for removable engagement of the reflective surface 12 such as a mirror. Using removably engageable reflective surfaces 12 as noted, provides the user with great utility by the provision of a means to adjust the optical image reflective characteristics of the reflected image 22 shown in FIG. 3 as a tooth.
[0040] As shown in FIG. 5 means for removable engagement of the reflective surface 12 may be provided by an adhesive back 24 or other means of removable engagement may be employed such as hook and loop fabric, a mechanical engagement such as a slide, or any such means for removable engagement as would occur to those skilled in the art.
[0041] Providing the reflective surface 12 in a removably engageable mode allows the optics and reflected image 22 to be customized for the job at hand. Using the adhesive 24 or other means of engagement of the reflective surface 12 adjacent to the distal end 11 , the reflective surface may be engaged which may have one or a combination of optical reflective properties including, image magnification optical properties, wide angle optical properties, corrective vision properties for users who wear glasses, or a split image yielding two angles reflecting two portions of the mouth adjacent to the distal 11 end of the retractor 14 .
[0042] In this preferred mode of the device 10 employing means for removable engagement of a reflective surface 12 , the device 10 can be made available in kits, or catalogs, featuring a plurality of different reflective surfaces 12 , each engageable with any of a plurality of optical reflective properties. Such may include one or a combination of reflective surfaces at increments of angles from of a plurality of angles of engagement relative to the retractor 14 surface adjacent to the distal end 11 , at increments of magnification or reduction of the image reflected, at increments of wide angle properties in the reflection, and in increments of vision correction for the reflective image to obviate corrective lenses of the user. Such a plurality of individual reflective surfaces, engageable to a dental retractor 14 as depicted, allows for great customization of the reflected image for the user. Additionally, the removably engageable reflective surfaces 12 also allow for retrofit of any type of dental retractor and not just as shown in the drawings. Such dental retractors may be straight, curved, or in any shape dental professionals may already be employing in their practice. In use, the user would choose the appropriate type of reflective surface 12 for their individual needs and engage it to the distal end of the retractor, thereby customizing the reflected image 22 for the user such as the surgeon, for the individual operation being performed. For instance, magnification might be a great aid in one type of surgery, whereas an unaltered reflection may be preferable to another professional or in another type of operation with the same professional.
[0043] Differing angles of reflection are an especially useful feature and can be provided by provision of the reflective surface 12 as in FIG. 6 where the rear side 26 angles relative to the reflective surface 12 and thereby places the reflective surface 12 when engaged to a dental retractor 14 at a different angle than the planar surface adjacent to the distal end 11 of any retractor being employed. While shown as adhesive 24 in FIG. 5 which would be convenient, FIG. 7 shows another means for removable engagement in the form of a bayonet type mount 28 on the back surface of the reflective surface 12 and a receiving cavity 30 on the distal end 11 of the retractor 14 .
[0044] Additionally, in a preferred mode of the device 10 in combination with the reflective surface 12 , as depicted in FIG. 1 a, the device 10 may have an engaged or engageable light source. Particularly preferred would be a light-emitting diode (LED) 34 to provide illumination directed at the area of the mouth to be reflected in the reflective surface 12 . The LED 34 may also be removably engageable to the retractor 12 and may employ a lens adapted to focus light on the area of the mouth or on the reflective surface 12 , or both, to better provide the user with a reflection in an otherwise dark mouth. LED's 34 are available in a very thin configuration and may be employed with adhesive attachments and provided herewith in the kit of reflective surfaces 12 . In kit form the lens 36 may be provided with differing lighting outputs to form a small spotlight or providing a wide angle of light to the mouth.
[0045] Finally, as shown in FIG. 1 a, a means for suction of liquid collecting in the mouth adjacent to the site of the surgery and distal end 11 of the retractor 14 may be provided in combination with the other components. Such a means for liquid collection would employ a conduit 40 formed upon or integral to the body of the retractor 14 which will commentate with a collection aperture 42 at the distal end 11 of the retractor 14 . The aperture 42 is positioned on the retractor 14 such that when the retractor 14 is engaged with the patient's mouth at its distal end 11 , the aperture 42 would be lower than the reflective surface 12 in the mouth. The other end of the conduit 40 is engaged using a nipple or other engagement means on the retractor 14 , to connect it to the suction system available in most dental offices. When so engaged, the aperture 42 will drain the mouth and serve to maintain fluid in the mouth, below the level of the mirrored surface 12 to aid in maintaining it as viewable.
[0046] The method and components shown in the drawings and described in detail herein disclose arrangements of elements of particular construction, and configuration for illustrating preferred embodiments of structure of the present dental retractor device with a reflective surface. It is to be understood, however, that elements of different construction and configuration, and using different steps and process procedures, and other arrangements thereof, other than those illustrated and described, may be employed for providing a surgical retrieval device and method in accordance with the spirit of this invention.
[0047] As such, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosure, and will be appreciated that in some instance some features of the invention could be employed without a corresponding use of other features, without departing from the scope of the invention as set forth in the following claims. All such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims.
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A dental retractor for employment during dental and oral surgery procedures. The device employs a reflective surface at a distal end which is conventionally used adjacent to the surgery site in the patient's mouth. The reflective surface eliminates the need for additional mirrors and such in the patient's mouth. Additionally provided is a proximal end that will adapted for ergonomic positioning in the hand of the user.
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BACKGROUND OF THE INVENTION
For making steel, solid pieces of ferrous metal such as scrap, pellets, etc., are melted down to form a melt which can be worked to the composition and characteristics desired for casting.
When the working is done by the ASEA-SKF practice, the melt is poured into a ladle furnace, of which there may be more than one, the ladle furnace being crane-carried and inserted in an AC induction coil for stirring, the ladle shell being non-magnetic. A roof is provided which can be lowered on the ladle and through which arcing electrodes project for adding heat to the melt, and also there is a cover which can be lowered on the ladle's top and evacuated for degassing the melt. In this way additions can be stirred into the melt, the melt can be further heated, and if desired, finally degassed. The ladle can be used for casting in the same way any steel ladle is used. This practice is disclosed by British specification No. 1,112,876.
To supply the melt required, it is most customary to charge steel scrap, pellets and possibly other solid ferrous pieces into an electric arc furnace having powered arcing electrodes, the arcs boring down into the pieces until ultimately a complete melt-down is effected. During this melt-down, there is arcing from piece to piece of the solid metal which produces concussions and smoke while introducing disturbances in the electrical network supplying the arcing electrode power. The furnace hearth and wall linings are subject to extremely high temperatures and erosion and must be repaired or replaced frequently. The arcing electrodes are consumable, and their cost of replacement is high. It is desirable to provide some better way for effecting a melt-down.
One other way is by the use of a crucible electric AC induction furnace, but this is time-consuming because it cannot be used with the same high power concentrations as can an arc furnace. When used for a melt-down, a crucible induction furnace is particularly sensitive to crucible leakage which damages its induction coil or coils and causes an expensive shutdown.
The object of the invention described below is to provide a better way for effecting a melt-down of solid pieces of metal so as to form a melt.
SUMMARY OF THE INVENTION
According to the invention, the solid pieces of metal for the melt-down are charged in a basin having a refractory inside. An electric AC induction heater is positioned above the basin and the charged pieces and operated so as to induce a heating AC current field in the pieces causing them to progressively melt and form a melt continuously collecting in the bottom of the basin. To avoid disturbances in the AC power supplied to the induction heater, the latter can be moved up and down and/or the level of the collecting melt controlled to keep the heating AC current field induced in the pieces and the collecting melt at a substantially constant impedance.
To prevent the collecting melt in the basin's bottom from progressively increasing in height, the melt can be continuously or intermittently tapped from the basin and into a refractory lined storage container, preferably provided with a heating means keeping the melt molten. For this the ladle furnace of the ASEA-SKF process can be used with a roof supplied with electric arcing electrodes used continuously or as required to keep the melt in the ladle molten. The arc power required is much less than is required for a melt-down using arcs.
The basin used can be relatively shallow as compared to its horizontal extent and may be provided with a lid in which the inductive heater is installed or connected so that the lid and heater form a unit bodily movable vertically and from over the basin for charging of the basin. The basin may be made with a tap hole provided with means for maintaining a relatively shallow pool in the basin's bottom, the basin being made so it can be tipped towards this tap hole for slag removal.
The basin can be made so that the heat losses are small. Because the basin's side wall need not be as high as the side wall of any usual melt-down furnace, the basin's side wall can be made with an unusually thick refractory lining providing unusually effective thermal insulation and, therefore, low heat loss. The level of the melt collecting in the basin's bottom can be kept low because the collecting melt can be continuously tapped into the storage ladle, so a high power concentration is possible without causing extensive molten metal flow due to the induction current. The induction heater itself with its coils and electrical equipment is not influenced by wear of the basin's lining because it is above the ladle and free from all molten metal. There is substantially no noise caused by the melt-down and there is very little if any production of gas. Assuming that for storage the ASEA-SKF type of ladle is used with a cover provided with arcing electrodes, the arcs are struck not with solid pieces of metal but with the melt collecting in the ladle via continuous or substantially continuous tapping of the melt collecting in the basin's bottom. Only a small amount of power is required to keep the collecting melt molten, and, therefore, the arcing electrode power and wear are small and little or no smoke or gases are produced.
When the ladle furnace is full, it can be crane-carried to the usual ASEA-SKF processing stations while a second replacement ladle continues to receive the melt tapped from the melt-down basin. The roof and its arcing electrodes used for the ladle storing the melt tapped from the basin, need not be the same as is used for the working of the melt, the heating requirement being low.
DESCRIPTION OF THE DRAWINGS
The accompanying drawings schematically illustrate the principles of the invention, the various views being as follows:
FIG. 1 is a plan view showing by outline diagram how two of the melt-down basins can be used in parallel;
FIG. 2 is a vertical cross section of one of the units;
FIG. 3 shows the outlines of several different contours of induction coils which may be used above the basin;
FIG. 4 diagrammatically shows how the inductor coils can be powered by means of separate transformers; and
FIG. 5 diagrammatically shows the use of AC converters.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 the outline diagram shows how two of the melt-down basin furnaces 1 and 2 can be positioned in parallel. The lid of each should be removable and provided with equipment for not only moving it up and down, but also to one side to permit charging of the basin as is illustrated by the broken lines 3 in the case of the basin 1. Both basins are shown with oblong rectangular shapes and their side walls which face each other are provided with tapping means 1a and 2a respectively for intermittently or continuously delivering the progressively forming melts from the basins to the ladle furnace 4 provided with a roof having arcing electrodes 5 powered by a source of electric power 6. When one of the basins is used for a melt-down, the other can be charged so that a continuous supply of melt can be delivered to the ladle furnace 4.
In FIG. 2 the tapping ends of the basin 1 is shown in vertical cross section. Its left-hand side is pivotally mounted at 6 so that the basin can tilt by swinging as indicated by the arrow 7, using a hydraulic lifter 8. The basin's bottom 1a slopes or declines towards the right. The basin's side wall 1b does not extend upwardly very far and without excessive cost it as well as the basin's bottom can be lined thickly, but the basin's extent in the horizontal direction can be substantially greater. It is because of these unique dimensions that the term "basin" has been used.
The right-hand side wall 12 of the basin has a tap hole 1c and the melt collecting from the melting charge 9 runs down the sloping bottom 1a of the basin towards and through the horizontal tap hole 1c into a slag separator 10 having a possibly removable cover 11. The basin side wall 12 above the tap hole 1c serves to hold back the unmelted solid part of the charge and the slag floating on the collecting melt beneath the charge, while inside of the slag separator 10 a dam 13 is provided which performs two functions. When the basin 1 is positioned with its bottom 1a horizontal, the dam 13 keeps the melt level at a height fixed by the dam's height, and, secondly, for deslagging when the basin 1 is tilted as shown in FIG. 2, the same holds back the melt while permitting the floating slag to run over the top of the dam and into a slag ladle. The operating temperature need be only a little above the melting temperature of the charge 9 so not very much slag should be expected.
The lid or roof assembly is shown at 14 with the inductor coil or coils 15 and core 16 connected together with the lid to form a unit. This unit should be refractory in nature, and because of its elongated oblong shape fitting the contour of the basin, is called a lid. The induced field in the charge can be spread uniformly over the entire charge in the basin by proper design of the inductor coil or coils and core structure.
This lid assembly is removable from the basin and is supported by a cantilever 17 which can be moved up and down by a hydraulically powered lifting column 18 which is pivotal to provide the action illustrated by the broken lines 3 in FIG. 1. The cantilever 17 can also mount the power lines 18 for the inductor coil or coils 15.
The slag separator 10 is itself provided with a vertical tap hole 20 through which normally the collecting melt pours downwardly. In FIG. 2 the deslagging operation is illustrated.
Various contours may be used for the design of the induction coil or coils 15, FIG. 3 showing at 22 an elongated form having rounded ends, at 23 showing an elongated rectangular form or oblong, and at 24 showing how two squares can be used, 25 showing a circular coil. In the case of the illustrated elongated basin shape, one of the designs shown at 22 through 24 would usually be used, but the single coil shown at 25 might be used in some instances.
Returning to FIG. 2 showing the basin tilted, the melt with slag floating on it is shown at 26, the dam 13 permitting the slag to skim or run off from the top of the melt for discharge into a slag ladle 27. Deslagging can be done when the ladle furnace shown in FIG. 1 is filled and carried away. After deslagging, another ladle furnace can take the place of the filled one.
To exemplify the practice of the new melt-down method, it is to be assumed that in FIG. 2 the basin 1 is lifted so its bottom is in its horizontal position, and that any of the usual kinds of scrap and possibly pellets are loaded in the furnace to form the charge 9, the lid or roof 14 being swung clear from the basin's top for this charging. With the lid moved back and lowered over the charge 9, using the manipulating equipment described before, power is turned on and the inductive heating of the charge starts. Inherently there can be practically no noise and little, if any, smoke. The solid pieces of metal gradually melt and begin to form the melt which as soon as it exceeds the height of the dam 13, begins to run off via the tap hole 20 in the slag removal chamber or spout 10, the basin wall 12 above the horizontal tap hole 1c holding back the as yet unmelted part of the charge and any slag.
At this time the furnace ladle 4 is positioned below the vertical tap hole 20 so as to receive the melt as it forms. Tapping should proceed so as to keep the melt in the basin bottom at a low level preventing the formation of meniscus or surface convexity which would cause variations in the impedance of the current induced in the charge. Raising and lowering of the lid 14 and its inductor unit can keep the impedance of the field induced in the charge and melt at a relatively constant value avoiding disturbances in the electric power supply.
The melt collecting in the ladle furnace shown at 4 in FIG. 1 is kept molten by the use of that furnace's roof electrodes 5 as required, but the arcing power used need only be sufficient to keep the collection of melt stored safely molten. Small arcing power is required for this purpose, and the arcs are struck with a melt and not solid pieces of metal, thus avoiding the usual noise and smoke, fumes and/or gases associated with a melt-down of solid pieces in an arc furnace.
When two of the basins are used in parallel, they can be alternately operated as previously indicated, permitting deslagging and/or charging of one while the other continues in operation. The ladle furnace roof can, if desired, be a permanent part of the entire installation so that a filled ladle can be quickly removed and transported, while another takes its place and uses the same roof.
In the foregoing manner a substantially continuous melt-down can be carried out. In the diagram of FIG. 4 the inductor power supply is from a three-phase network 27' via separate transformers 28 and 29 with parallel capacitors 30 and 31, to the inductors 32 and 33 in the lid or roof of the melt-down furnace basin. These may be like the inductors 24 in FIG. 3. Symmetrization and compensation can be effected via thyristor-connected capacitors and reactors in the box shown at 34.
FIG. 5 shows the supply with self-converting converters from a three-phase network 27'. The supply takes place via a transformer 35 and two parallel-working rectifiers 36 and 37 and an inverter 38, the output side of which feeds the inductor 39 which is provided with a parallel capacitor 40. It is thus possible to select any desired frequency for feeding the inductor 39. In this case the inductor can be wound as shown at 22, 23 or 25 in FIG. 3. With several inductor coils the supply is suitably carried out with individual single-phase transformers as shown in FIG. 4.
Although the apparatus and method of this invention is primarily intended for effecting a melt-down, it is conceivable that alloying may occur during the melt-down. For example, by selection of scrap together with possibly the use of iron pellets, alloying may be possible.
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Solid pieces of metal, such as steel scrap and ferrous pellets, are charged in a basin having a refractory inside and progressively melted down by an electric induction heater positioned above the basin and the charge. As melt collects in the bottom of the basin it is continuously or intermittently tapped into a storage container having heating means for keeping the melt molten. This prevents the melt level in the basin's bottom from rising uncontrollably.
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This application claims the benefit of U.S. Provisional Application No. 60/105,401, filed Oct. 23, 1998, and entitled “DATABASE DESIGN AND MAINTENANCE SYSTEM,” which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a database system, and more particularly to a database design and maintenance system and method that includes a software suite designed to assist users with creating, storing, updating and reusing full-text and bibliographic databases.
2. Description of the Related Art
In the digital age, a growing number of companies are realizing the need to better organize their information. Many of these companies have accumulated a vast amount of information and data over the years, typically in paper form. Storing this information has required many companies to rent additional storage space for documents that cannot be destroyed or must otherwise be retained. Consequently, locating necessary documents from storage files has become a complex, cumbersome and often time-consuming task. If documents or files are misplaced, the chance of finding the desired information is low.
Many companies have digitized their information to store in a database. This information is typically available through a network to facilitate multiple user access. However, data storage and retrieval in the digital age continues to be problematic due to differences in platforms, systems, proprietary formats, and media. These differences make it difficult to effectively store and retrieve large volumes of data. For example, some database management systems are not configured to handle variable length fields to facilitate input of textual data. In addition, use of different software tools for managing database functionality often create compatibility issues. That is, many software components necessary for effective database management typically fall short of performing seamlessly for the user. These problems may require the database to be inactive for repair and maintenance. Any such downtime could considerably affect a company that relies on its database in the normal course of business.
In view of the foregoing, there is a need for a system and method that simplifies database design and maintenance by offering seamless integration of software tools to effectively store and retrieve data.
SUMMARY OF THE INVENTION
Embodiments consistent with the present invention address the foregoing needs with a database design and maintenance system and method that includes a software suite designed to assist users with creating, storing, updating and reusing full-text and bibliographic databases. The software suite includes three components configured to operate on any Java-enabled server. The first component is an intranet system for document entry, editing, and viewing. The second component is an indexer that includes concept extracting, statistical collecting, and rule building functionality. For example, when a text document is entered into the intranet system, the concept extractor scans the document to determine appropriate subject terms for identifying the document. These subject terms are reviewed by a human indexer and assigned to the document. The statistical collecting function analyzes the concept extractor's performance in finding appropriate indexing terms and maintains a record of the hits, misses, and noise. If a term is consistently missed by the concept extractor, as determined by the statistical collector, the rule building function of the indexer creates a new rule for finding appropriate indexing terms. The third component is a thesaurus management system that allows users to write and manage their own vocabulary of specialized terms, or expand upon an existing thesaurus employed in the database design and maintenance system. Thus, if the statistical collecting function of the indexer shows the need for a subject term that is not included in the thesaurus, the subject term can be entered into the thesaurus. A feedback loop is created by the repetition of this process, ensuring that changes in the database vocabulary are reflected during retrieval of information.
An aspect of the invention provides a database design and maintenance system, comprising a database management means for storing textual data in a storage device, the database management means having a user interface to facilitate entry, editing and viewing of the textual data; an indexing means in communication with the database management means for indexing the textual data entered into the database management means; and a thesaurus means in communication with the database management means for managing a vocabulary of terms related to the textual data.
Another aspect of the invention provides a method for maintaining a database, comprising the steps of generating a graphical user interface; receiving textual data; determining at least one indexing term to associate with the textual data for storage and retrieval; displaying at least one indexing term for user selection; associating the selected indexing term with the textual data; and storing the textual data in a storage device.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the preceding general description and the following detailed description, explain the principles of the invention.
In the drawings:
FIG. 1 is a diagram of a database design and maintenance system consistent with the present invention;
FIG. 2 is a block diagram of software components included in a database design and maintenance system consistent with the present invention;
FIG. 3 is a flowchart of a method for implementing an intranet software component of the database design and maintenance system consistent with the present invention;
FIG. 4 is a flow diagram of an indexing software component of the database design and maintenance system consistent with the present invention;
FIG. 5 is an example of an indexing search routine consistent with the present invention;
FIG. 6 is a flowchart of a method for implementing an indexing software component of the database design and maintenance system, consistent with the present invention;
FIG. 7 is a flow diagram of a knowledge base function of a database design and maintenance system consistent with the present invention; and
FIG. 8 is a flowchart of a method for implementing a thesaurus component of the database design and maintenance system consistent with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a diagram of a database design and maintenance system 100 consistent with the present invention. System 100 includes a group of components that may be configured to transfer data over a wide area network (WAN) (e.g., the Internet) or a local area network (LAN) (e.g., an intranet). For purposes of illustration, system 100 includes a data storage device 110 (i.e., a database), a server 120 and end terminals 130 for intranet or Internet applications. One skilled in the art will appreciate that system 100 may have many different configurations depending on the desired database environment.
Data storage device 110 serves as a database for information stored and retrieved on system 100 . Data storage device 110 may be any commercially available data storage device that facilitates high-speed access and retrieval of stored data (e.g., an optical disc storage device). System 100 may include one or more data storage devices depending on the anticipated volume of data for storage.
Server 120 includes a memory 140 , a processor 150 and a storage device 160 for software applications. Server 120 operates to control the flow of information between data storage device 110 and end terminals 130 and may be a commercially available server (e.g., a Sun Solaris® server). Memory 140 is preferably random access memory (RAM) (e.g., 64 megabytes). The amount of memory necessary for optimal server 120 performance may vary depending on the configuration of system 100 . Processor 150 is preferably a high-speed processor (e.g., at least 200 Mhz), such as a Pentium® processor manufactured by Intel Corporation. Processor 150 communicates with memory 140 and storage device 160 to control the operation of server 120 . Storage device 160 is a hard drive or other data storage device capable of storing software applications, including an operating system 170 , Java® virtual machine 180 , and database design and maintenance software 190 .
Operating system 170 may be a Linux, Macintosh, Windows NT, Unix, Solaris or other operating system capable of running on servers. Including Java virtual machine 180 in storage device 160 ensures that server 120 is a Java-enabled server for intranet and Internet applications. Database design and maintenance software 190 facilitates storage and retrieval of information between data storage device 110 and end terminals 130 (e.g., desktops computers). A detailed discussion of database design and maintenance software 190 begins with FIG. 2 described below.
FIG. 2 is a block diagram of software components included in database design and maintenance software 190 consistent with the present invention. Software 190 preferably includes a plurality of software components, each of which provides a specific function of system 100 . These software components include an intranet software module 200 , an indexer software module 210 , and a thesaurus software module 250 . These software modules are configured to operate independently or in harmony depending on the database application environment.
Intranet software module 200 includes a document management tool configured to handle variable length textual data. Preferably, intranet software module 200 is written in Java and uses Extensible Markup Language (XML) to store and transmit data over system 100 (e.g., using TCP/IP protocol). XML may also be used to configure each database in system 100 . XML permits intranet software module 200 , for example, to output data over the Internet or for typesetting. Intranet software module 200 generates a graphical user interface (GUI) either at the server or client terminals that is viewable, for example, through a web browser 205 that runs Java applets. The GUI permits administrators to edit server functions and nested data structures associated with XML documents. The GUI further supports data entry, viewing, editing, sorting and other text management functions. As a modular based application, intranet software module 200 can generate application-specific viewing and editing screens, without additional programming.
The GUI of intranet software module 200 preferably supports a plurality of interactive functions. For example, the GUI can generate an edit screen for entering new data into system 100 . The edit screen may include several fields for entering data, such as single value fields, multi-value fields, free text fields and subfields. Single-value fields accept only one entry while multi-value fields hold more than one entry. Free text fields require no specific codes or guidelines for the entered data values and are generally used for information written in paragraph format (e.g., abstracts and notes fields). Subfields are new multi-value fields for entering an additional layer of information into system 100 . A subfield may include single-value fields, multi-value fields, free text fields, or additional subfields. Upon entering data into the appropriate fields, a user can select an indexing function of database design and maintenance software 190 via the GUI.
Indexer software module 210 enables human indexers to increase their indexing efficiency and consistency. In particular, indexer software module 210 facilitates selection of terms from a variety of database sources, such as controlled vocabularies, authority files, or thesauri. When new data in entered into system 100 , indexer software module 210 generates a list of approved indexing terms for selection thus, eliminating the need to manually generate indexing terms. To provide full indexing functionality, indexer software module 210 includes a plurality of software tools, including a concept extractor 220 , a statistical collector 230 , and a rule builder 240 . A detailed description of these software tools is provided below with respect to FIGS. 4-6 .
To aid in determining appropriate indexing terms for new textual data, database design and maintenance software 190 includes a thesaurus software module 250 for associating related vocabulary terms with subject terms. For example, if a suggested indexing term is “music,” activating the thesaurus through the GUI may provide additional vocabulary terms, such as “Musician,” “Music history,” and “Musical instruments.” In addition, thesaurus software module 250 enables users to manage their own vocabulary of specialized terms, or to use and expand upon an existing thesaurus obtained from an external source. In addition, thesaurus software module 250 facilitates management of structured vocabularies from a complete thesaurus to authority files, and may be used independently, or with intranet software module 200 and indexer software module 210 . Preferably, thesaurus software module 250 includes “broader term” and “narrower term” hierarchical structures, “use” and “used for” references, and “history,” “related terms,” and “scope notes” functionality for different applications. A more detailed discussion of thesaurus software module 250 is provided below with reference to FIGS. 7-8 .
Additional features of intranet software module 200 include searching functions. For example, intranet software module 200 permits users to search for records already stored in the database. The search function may be activated from any of the entry fields described above or a global search may be implemented to automatically search all data entered into each of the entry fields. The GUI of intranet software module 200 displays the search results, including “hit” information such as the title and record number of the stored data. One skilled in the art will recognize that intranet software module 200 may include additional features to facilitate database design and maintenance as described herein.
FIG. 3 is a flowchart of a method for implementing intranet software module 200 of database design and maintenance system 100 consistent with the present invention. The method begins with the step of generating an edit screen on the GUI to receive data (step 300 ). More specifically, the edit screen is configured to receive textual data in one or more fields generated on the edit screen. Once the textual information is entered into the edit screen, the user can select an indexing function which determines appropriate indexing terms for storing the data (step 310 ). The indexing terms are subsequently displayed to the user for selection (step 320 ). The user can either select from the list of suggested terms or input her own indexing terms for storing the data. The selected terms are then associated with the data (step 330 ), which is stored in accordance with the indexing term (step 340 ). Once stored, the data can be easily retrieved through the GUI simply be using the indexing term associated with the desired data (step 350 ).
FIG. 4 is a flow diagram 400 of indexer software module 210 of database design and maintenance software 190 consistent with the present invention. Flow diagram 400 begins with entering textual data into system 100 , through the GUI of intranet software module 200 (step 405 ). The textual data is then sent to concept extractor 220 which determines appropriate indexing terms for the textual data using a rule-based system described below (step 410 ).
The initial screen of indexer software module 210 preferably displays multiple options to the user, including “Get Previous Statistics”, “Make Statistics,” “Edit Rules,” and “Search Rules.” One skilled in the art will recognize that additional options may be offered to the user on the initial screen of indexer software module 210 .
Selecting the “Get Previous Statistics” option displays a list of previously generated batches of statistical data generated by statistical collector 230 (step 415 ). A batch is a group of database documents with hit, miss, and noise statistics. “Hit” statistics refers to a list of suggested indexing terms selected by the user. “Miss” statistics refers to a list of indexing terms indexer software module 210 did not suggest, but were manually selected by the user. “Noise” refers to a list of indexing terms indexer software module 210 did suggest, but were not selected by the user. Preferably, on the Statistics display, statistics are sorted with the term with the most misses or noise at the top. After each term, the number of times it was missed (in the case of misses) or suggested (in the case of noise) is provided.
Selecting a displayed statistical term preferably opens a Term display. Whether the term is related to “Miss” or “Noise” statistics is indicated on the Term display. The Term display further shows each database document where the selected term is being considered. For example, “Key: 0458363 Editor: vince” indicates that document number 0458363, created by the editor Vince, contains a miss or a noise (depending on what was selected).
Selecting a database document via the Term display will preferably open a Document display which includes (a) document information (e.g., title, series title, and abstract); (b) suggested terms, the rule it used to invoke each term, and the number of times indexer software module 210 accessed that rule (e.g., “History of film—(2) history(1) film(1)”); (c) a list of used terms, or terms the user chose to index the record; and (d) all the options needed to edit the rule base (e.g., an Enter Rule field and New Rule, Search RuleBase, Retry, and Back options). The Enter rule field permits a user to enter an existing rule for display. The New Rule option allows a user to create a new rule. The Search RuleBase option allows the user to search for an existing rule. The Retry option compares the current document with new rules created by the user. The Back option exits the existing GUI.
The Make Statistics option uses statistics collected by statistical collector 230 to create a batch (step 420 ). That is, this option uses all the documents created by indexer software module 210 since the last computation of statistics. A list of prior “Hit,” “Miss,” and “Noise” statistics may be generated by statistical collector 230 in the manner described above using the Get Previous Statistics option (step 425 ).
The Edit Rules option generates a display with preferably a text-to-match field, a rule field, and selection options. From this display, a user can enter text-to-match information in the text-to-match field for a new rule and enter the body of the rule in the rule field. Upon entering the foregoing information, indexer software module 210 preferably allows the user to select from several options (e.g., Check Rule, Save, Quit, Quit without Saving, Search Rules, and Delete Rules). To make a new rule with the same body as an existing rule, but a different text-to-match, a user can display the existing rule and change the text in the text-to-match field. In this instance, a new rule is created without modifying the old one. Also, once a rule is deleted, the text does not disappear immediately from the screen.
The Search Rules option creates a search display that preferably provides the user with multiple search options (e.g., “Matching Text” and “Subject Term” options). A Matching Text option, for example, searches for text that appears in the text-to-match. A Subject Term option, for example, displays a list of rules that invoke a specified subject term. Any rules that are modified by the user subsequent to a search, or newly created by the user as set forth above, may be suggested to rule builder 240 as feedback (step 428 ). The suggested rules are sent to rule builder 240 (step 430 ).
Rule builder 240 is an interactive application that uses information from a master knowledge base (step 435 ) and thesaurus software module 250 (step 440 ) to develop rules for generating indexing terms for the storage and retrieval of data. The master knowledge base includes a vast collection of vocabulary terms, grammatical rules and other information which permits database design and maintenance software 190 to recognize and grammatically interpret new data. Thesaurus software module 250 includes a database of thesaurus terms that associates related terms to subject terms suggested by the batch mode indexer engine. Rule builder 240 uses the thesaurus terms to create a broader range of indexer rules for generating a broad range of suggested indexing terms for the user to select.
An indexer rule preferably includes a “text-to-match” component and a “body” component. The text-to-match component is a string of text the indexer engine searches for in either the abstract, title, or series title of a record, in order to invoke a rule. The body of the rule includes the conditions the record must satisfy in order to suggest an indexing term. Rule builder module 240 preferably includes IDENTITY rules, SYNONYM rules, IF rules, IF-ELSE rules, IF-ELSE-IF rules, IF—IF rules, TRUNCATION rules, COMPOUND rules, NOT rules, and NULL rules.
IDENTITY rules are rules where the text-to-match and the thesaurus term are identical. These rules can be generated programmatically from a controlled vocabulary. For example, for a text-to-match component of “guam,” rule builder 240 may generate an identity rule, such as “USE Guam.” The text after USE should be worded exactly like the thesaurus term, including capitalization. In the text-to-match component, capitalization may be ignored, and plurals and singulars may be implied. For example, if the text-to-match is “dog,” indexer software module 210 will match “dog” and “dogs.” Conversely, if the text to match is “cats,” indexer software module 210 will match “cats” and “cat.”
SYNONYM rules are essentially the same as Identity rules, except the text-to-match and thesaurus term are different. For example, if the text-to-match term is “burglary,” rule builder module 240 may generate a Synonym rule, such as “USE Theft.”
IF rules preferably include a set of conditions (e.g., a string of words) that must be met, or that the entered text must contain, in order for the indexing term to be invoked. Preferably, the IF statement is closed with an ENDIF command. Along with the IF statement, there should be a proximity indicator to prompt indexer software module 210 where to search for these conditions in relation to the text-to-match. The three proximity indicators preferably are NEAR, WITH, and MENTIONS. Examples of IF rules are provided below.
NEAR requires the condition to occur within three words of the text to match. text to match: building IF (NEAR “security”) USE Crime prevention ENDIF
In this example, if “security” occurs within three words of “building,” use the thesaurus term “Crime prevention.”
WITH requires the condition to occur anywhere within the same sentence as the text to match. text to match: hospitals IF (WITH “psychiatric”) USE Mental health facilities ENDIF
In this example, if “psychiatric” occurs within the same sentence as “hospitals,” the indexing term “Mental health facilities” is used.
MENTIONS requires the condition to occur anywhere within the abstract, title, or series title. text to match: theater IF (MENTIONS “improvisational”) USE Experimental theatre ENDIF
In this example, if “improvisational” occurs within the same record as “theater,” the indexing term “Experimental theatre” is used. Conditions may be imposed on the IF rules, such as requiring the text-to-match to be in all capital letters or to begin a sentence.
With IF-ELSE rules, preferably ELSE is used to offer the user a variety of other options. Thus, if the initial IF statement is false, indexer software module 210 provides an alternative term. An example of the IF-ELSE rules is set forth below.
text to match: norwegian IF (MENTIONS “language”) USE Norwegian language ELSE USE Norway ENDIF
That is, if the record contains the word “norwegian,” and the word “language” occurs anywhere within that same record, the phrase “Norwegian language” should be used as the indexing term. However, if the record doesn't contain the word “language,” the term “Norway” should be used instead. For IF-ELSE rules, indexer software module 210 will present the user with either “Norwegian language” or “Norway,” but not both.
For IF-ELSE-IF rules, another set of conditions (i.e., a second IF statement) is added to the IF-ELSE rule. The following is an example of the IF-ELSE-IF rule.
text to match: norwegian IF (MENTIONS “language”) USE Norwegian language ELSE IF (MENTIONS “country”) USE Norway ENDIF ENDIF
If the record does not contain the word “language,” indexer software module 210 will not automatically use the term “Norway.” The additional IF statement, in this example, requires that the word “country” be mentioned before “Norway.” For IF-ELSE-IF rules, indexer software module 210 will present the user with “country” or “Norway,” but not both.
An IF—IF rule may be used to prompt indexer software module 210 to suggest both “Norway” and “Norwegian language” to the user as possible indexing terms. For example, to suggest both indexing terms to the user, the rule may be written as two separate statements (i.e., an IF—IF rule).
text to match: norwegian IF (MENTIONS “language”) USE Norwegian language ENDIF IF (MENTIONS “country”) USE Norway ENDIF
In this example, the placement of the ENDIFs and the lack of an ELSE is important. Once indexer software module 210 encounters the first ENDIF, it stops. When indexer software module 210 encounters the second IF, it starts over again, treating the statement as a new rule. Indexer software module 210 may be programmed to include a variety of conditions and other parameters to achieve the desired results (e.g., to use “Norway” or “Norwegian language” or both depending on specified conditions).
For TRUNCATION rules, an asterisk may be used to indicate truncation. Truncation may be allowed to the left, to the right, or between words, but not in the middle of a word, and not as the first or last word. So, for example, using the TRUNCATION rule, “teach*” will match “teach,” “teaching,” “teacher,” and other words with “teach” as the prefix. In addition, the term “*ware” will match “software,” “hardware,” “kitchenware,” “beware,” and other terms with “ware” as a suffix. Moreover, the phrase “drinking * driving” will match “drinking and driving,” “drinking while driving,” and “drinking phone driving.” In this example, the asterisk between words only represents one word. The following is an example of the TRUNCATION rule.
text to match: grow*
IF (WITH “crystal*”)
USE Laboratory techniques
ENDIF
COMPOUND rules preferably operate in the same way as the foregoing rules, except that COMPOUND rules provide more options within each IF statement. For example, text strings are separated by OR or AND to either broaden or narrow the matching criteria. OR requires that at least one of the conditions be true in order to be evaluated as true. The following is an example using OR.
text to match: geometry IF (WITH “plane” OR WITH “euclid*”) USE Euclidean geometry ENDIF
Thus, using COMPOUND rules, if “plane” is in the same sentence as “geometry,” or “euclid” is in the same sentence as “geometry,” indexer software module 210 will suggest “Euclidean geometry” to the user as an indexing term. AND requires that both (or all) of the conditions are true in order to be evaluated as true. The following is an example using AND.
text to match: geometry IF (WITH “plane” AND WITH “euclid*”) USE Euclidean geometry ENDIF
In this example, the IF statement requires both “plane” and “euclid” to be in the same sentence as “geometry” in order for indexer software module 210 to suggest “Euclidean geometry.” For COMPOUND rules, an IF statement can contain as many ORs or ANDs as needed. These connectors can even be combined as shown in the following example.
text to match: psychological IF (WITH “disorder” OR WITH “problem”) AND (WITH “treatment” OR WITH “care”)) USE Treatment of psychological disorders ENDIF
Thus, in this example, if either “disorder” or “problem” occurs in the same sentence as “psychological,” and either “treatment” or “care” also occurs in that sentence, indexer software module 210 will suggest to the user “Treatment of psychological disorders” as an indexing term.
For NOT rules, NOT can be used before MENTIONS, WITH, or NEAR, to indicate that indexer software module 210 will only suggest an indexing term if the string does not occur within a specified proximity. The following is an example of a NOT rule.
text to match: bear IF (NOT NEAR “chicago”) USE Wild animals ENDIF
In this example, indexer software component will only suggest “Wild animals” to the user as an indexing term if “bear” and “Chicago” are not within three words of each other. NOT statements may get more complicated when they are also compound statements. The AND connector may be used to get the same effect that the OR connector has provided in other statements. An example of this condition follows.
text to match: animation IF (NOT WITH “includes” AND NOT WITH “contains”) USE Animated photography ENDIF
In the foregoing example, indexer software module 210 will suggest “Animated photography” to the user only if neither “includes” nor “contains” appears in the same sentence as “animation.” The reason an AND is used instead of an OR is based on the Boolean definitions of AND and OR. An AND statement is true only if both (or all) parts of the statement are evaluated as true. An OR statement is true if just one part is evaluated as true.
Indexer software module 210 uses the NULL rule to ignore a string of text in a record (i.e., not use the text string as a text-to-match). An example of the NULL rule is provided below.
text to match: set in motion
NULL
In this example, when indexer software module 210 encounters the phrase “set in motion,” it will not use the word “set” to match the indexing term. An implied NULL rule may be used with an IF-ELSE statement by eliminating the USE command. An example of an implied NULL rule is as follows.
text to match: segments
IF (NEAR “film” OR NEAR “video” OR NEAR “movie”) ELSE USE Segments ENDIF
After creating a rule consistent with the foregoing, rule builder 240 may generate management reports which may include a variety of information, such as a list of the existing rules and the number of times each rule has been used (step 445 ).
After rule builder 240 has developed developed new rules for generating additional indexing terms to suggest to users, the new rules and terms are added to a working knowledge base (step 450 ). The working knowledge base is periodically updated with new or modified rules and terms in order to adapt to a particular user environment. That is, a working knowledge base consistent with the present invention enables indexer software module 210 to “learn” as new documents are entered into the database of system 100 . The batch mode indexer engine can access the working knowledge base when receiving new documents into system 100 .
Using the updated working knowledge base, the batch mode indexer engine can display suggested indexing terms for newly received data (step 460 ). The user can then choose from the suggested indexing terms generated by indexer software module 210 or manually enter different terms. (step 465 ). If the user chooses to manually enter indexing terms and thus, not choose the automatically generated terms, the new terms are forwarded to rule builder 240 for analysis and for generating new rules for subsequent documents entered into the database of system 100 (step 428 ). If the user selects the terms suggested by indexer software module 210 , the electronic file created for the newly entered data is edited to include the selected indexing term or terms (step 470 ). The terms are merged before storing the new data into the database of system 100 to ensure that any of the selected terms may be entered by a user to retrieve the stored data. The indexed electronic file with the data and indexing terms is then uploaded into data storage device 110 (step 475 ).
FIG. 5 is an example of an indexing search routine consistent with the present invention. This example illustrates entry of new textual data into system 100 . Indexer software module 210 includes concept extractor 220 to extract concepts from text data entered into intranet software module 200 . As illustrated in FIG. 5 , concept extractor 220 identifies a first four-word phrase in the input file which includes a keyword “photogrametric.” Concept extractor 220 first buffers the phrase “and photogrametric survey sections” and attempts to extract a subject term that satisfies a rule in the master knowledge base (step 500 ). A search is initiated by indexer software module 210 to match the buffered string with existing text in the master knowledge base (step 510 ). Indexer software module 210 deletes the last word in the text string and again compares the remaining phrase with the master knowledge base (step 520 ). Indexer software module 210 deletes any additional words (steps 530 and 540 ) and compares the remaining text with the master knowledge database, respectively. If no match is found with the last remaining word, a second four-word phrase including “photogrametric” is buffered (step 550 ). Indexer software module 210 repeats the foregoing iterative process (steps 560 and 570 ) until a match is found (step 580 ). After the match is found, the rule associated with the keyword is read and the appropriate indexing term is assigned to the new input file.
FIG. 6 is a flowchart of a method for implementing indexer software module 210 of database design and maintenance system 100 , consistent with the present invention. The method begins with scanning data entered into intranet software component 200 and extracting an indexing term therefrom (step 600 ). This step is performed by concept extractor 220 . The next steps include analyzing and recording the usage of the indexing term for statistical data (step 620 ) and updating the statistical data (step 640 ). These steps are performed by statistical collector 230 . A rule to search for the stored data is then implemented, if it currently exists, or is developed to search for the data upon storage (step 660 ). One skilled in the art will appreciate that additional steps may be taken by indexer software module 210 to achieve a desired operation consistent with the present invention.
FIG. 7 is a flow diagram of a knowledge base function of database design and maintenance system consistent with the present invention. The flow diagram begins with entering textual data into intranet software module 200 (step 710 ). Thesaurus terms may also be entered into an existing thesaurus database or used to create a new thesaurus database (step 720 ). The thesaurus database includes subject terms and relationships between terms stored in a hierarchical or controlled vocabulary format. The thesaurus database is created, maintained and organized by thesaurus software module 250 which is accessible through the GUI generated by intranet software module 200 . Upon selecting the thesaurus function through the GUI, a Thesaurus display is preferably generated which allows the user to add, delete, change terms in the thesaurus database. The user may also move terms to different places in the hierarchy. In addition, the user can create certain words in the thesaurus database that should be replaced or deleted from a particular rule or relationship (e.g., removing “fast” from a relationship including “speed” and “quick”). A user can create a relationship between two or more valid thesaurus terms by entering a primary thesaurus term and all desired related terms in appropriate field of the Thesaurus display. A relationship between two or more valid thesaurus terms may be removed in a similar manner.
The Thesaurus display also may allow users to enter notes and history information regarding a particular term or relationship between terms. To the extent any changes or additions of notes and/or historical information impacts the hierarchical order of the thesaurus terms and relationships, the hierarchy may be automatically reordered to reflect such changes. In addition, a user can search for a thesaurus term through the Thesaurus display simply by entering the term in the appropriate field on the Thesaurus display. Thesaurus software module 250 will then retrieve all of the terms in the database that are related to the entered term. Search terms may be truncated to yield a broader range of results.
Any changes to the thesaurus database are updated and used to create and modify rules for generating suggested indexing terms (step 730 ). A trial index of suggested terms is then created (step 740 ). The trial index is then forwarded to an index editor which may modify or add terms to the thesaurus based on new or modified rules (step 750 ). A final index is then created with the updated thesaurus changes (step 760 ). Database design and maintenance software 190 then compares the final index with the trial index (step 770 ) to determine any changes (step 780 ). The changes are then forwarded to step 730 . The foregoing iteration preferably continues to constantly upgrade the knowledge base of system 100 .
FIG. 8 is a flowchart of a method for implementing thesaurus software module 250 of database design and maintenance system 100 consistent with the present invention. The method begins with retrieving a thesaurus from an external source (step 800 ). The “external source” may include thesaurus terms manually entered into system 100 or a thesaurus imported from an external location. Specialized vocabulary terms are then added to the thesaurus database for inclusion in rules to facilitate a search for stored data (step 820 ). In addition to adding terms to the thesaurus, the vocabulary terms and/or their relationships may be edited to reflect changes in indexing terms (step 840 ). These edited terms and/or relationships may also be used to create or modify existing rules for suggesting indexing terms to a user.
Embodiments consistent with the present invention provide a database design and maintenance system that assist users with creating, storing, updating and reusing full-text and bibliographic databases. The software suite includes an intranet system for document entry, editing, and viewing, an indexer for concept extracting, statistical collecting, and rule building functionality, and a thesaurus for allowing users to write and manage their own vocabulary of specialized terms, or expand upon an existing thesaurus employed in the database production and maintenance system. These components of the software suite may operated independently or be integrated to provide seamless performance in database design and maintenance.
While only some embodiments and methods consistent with the present invention have been described, those skilled in the art will understand that various changes and modifications may be made to these embodiments, and equivalents may be substituted for elements in these embodiments, without departing from the true scope of the invention.
In addition, many modifications may be made to adapt a particular element, technique or implementation to the teachings of the present invention without departing from the central scope of the invention. Therefore, this invention should not be limited to the particular embodiments and methods disclosed herein, but should include all embodiments falling within the scope of the appended claims.
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A database design and maintenance system and method includes a software suite designed to assist users with creating, storing, updating and reusing full-text and bibliographic databases. The software suite includes three components configured to operate on any Java-enabled server. The first component is an intranet system for document entry, editing, and viewing. The second component is an indexer that includes concept extracting, statistical collecting, and rule building functionality. For example, when a text document is entered into the intranet system, the concept extractor scans the document to determine appropriate subject terms for identifying the document. These subject terms are reviewed by a human indexer and assigned to the document. The statistical collecting function analyzes the concept extractor's performance in finding appropriate indexing terms and maintains a record of the hits, misses, and noise. If a term is consistently missed by the concept extractor, the rule building function of the indexer creates a new rule for finding appropriate indexing terms. The third component is a thesaurus management system that allows users to write and manage their own vocabulary of specialized terms, or expand upon an existing thesaurus employed in the database design and maintenance system. Thus, if the statistical collecting function of the indexer shows the need for a subject term that is not included in the thesaurus, the subject term can be entered into the thesaurus. The database design and maintenance system and method brings together technology and protocols for an entirely different approach to text, taxonomy and catalog management.
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BACKGROUND OF THE DISCLOSURE
In completion of a well, one process presently in favor is the use of a tubing conveyed perforating assembly suspended on a tubing string to form perforations at a specified depth in the well. The TCP process typically involves suspending a set of perforating guns (ranging from a few to several hundred) at the lower end of the tubing string. The tubing string is assembled at the well head and lowered into the well. The TCP assembly is guided by a packer to register the TCP assembly opposite the formation of interest prior to forming the perforations. Ordinarily, a detonating bar is dropped free fall in the tubing string. The bar strikes the top end of the apparatus with the TCP assembly thereby triggering detonation. The detonating bar normally weighs quite a bit. Moreover, the tubing string can be quite long, easily more than 10,000 feet, and the bar may well reach significant velocity as it falls into the well. If the bar falls freely without impediment, it will travel with sufficient kinetic energy that it may do damage to the equipment at the top end of the TCP assembly. Because of this, it is desirable to retard the rate of fall of the detonating bar. One way to do this is to place a standing column of liquid above the TCP assembly so that the detonating bar is retarded by the liquid. This regulates detonating bar velocity to assure that the kinetic energy in the impact is in an acceptable range.
One problem which makes detonating bar velocity variable is a change in viscosity of the fluid in the tubing string. Assume as an easy example that the tubing string is filled with certain depth with clean water. This will provide a known retardation to the velocity of the drop bar. On the other hand, if the water mixes with drilling fluids or formation fluids or both, it can easily become quite different in physical characteristics and thereby provide significantly different retardation to the velocity of the detonating bar. It is therefore desirable to limit commingling of the fluids so that drilling fluids or formation fluids on the exterior of the tubing string do not invade the string and thereby change the viscosity of the standing column of liquid. It is particularly possible to mix drilling fluid in the water and thereby significantly change the retardation of the water to the dropped detonating bar.
The present apparatus enables isolation of the standing column of water above the TCP assembly. Moreover, there maybe variations in downhole pressure. The present apparatus accommodates pressure differentials between the column of standing fluid above the TCP assembly and the exterior in the annulus of the well. Briefly, this apparatus includes a floating piston assembly which is enclosed in a suitable sub. The piston assembly can ride up and down to achieve a pressure balance. The floating piston assembly is sealed over by glass disk. When the detonating bar is dropped, it shatters the glass disk and passes through it. The sacrificial glass disk isolates fluid therebelow to assure that that fluid is clean. Thus, the floating piston assembly rises and falls for clean fluid isolation. Moreover, should pressure increase below the glass disk, an O-ring valve assembly vents fluid in one direction only, thereby accomplishing controllable pressure relief, all as will be set forth in detail herein after.
DETAILED DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows a tubing conveyed perforating assembly on a tubing string suspended in a well wherein the isolation tool of the present disclosure is installed in the tubing string to protect a standing column of clean fluid in the tubing string; and
FIG. 2 is a detailed sectional view through the isolation tool of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 of the drawings. There, a well has been shown where production steps are being undertaken including the detonation of shaped charges to form perforations. The well is cased at 10 and a packer or other landing nipple is located at 12 to support a TCP assembly 14. The assembly 14 is of any suitable length, and includes detonating apparatus as well as a specified number of shaped charges. They point radially outwardly at selected spacing and angular positions to perforate the casing 10. They will also perforate through the surrounding cement 16 which anchors the casing in location. The perforations are formed into adjacent formations including a sand of interest indicated at 18. It is intended that production be obtained from the sand, and to this end, the TCP assembly 14 is positioned so that the perforations are formed at the proper depth in a required number. The TCP assembly 14 is thus placed in registry with a packer or other landing device which assures that the perforations are formed at the proper depth.
The TCP assembly supports an internally located detonator mechanism (at the upper end) which is actuated by a dropped detonating bar. The numeral 20 represents such a detonating bar traveling free fall in the tubing string. The tubing string is assembled above the TCP assembly 14 by placing a first tubing section 22 thereabove. It has a desired length. The isolation tool of the present disclosure is located thereabove at 24 in the tubing string. Additional joints of tubing are added at 26 to obtain the necessary length such that the TCP assembly is located at the proper depth. The tubing 26 can be several thousand feet in length. By contrast, the tubing 22 (above the TCP assembly and below the isolation tool) is a desired length and is filled with a clean fluid. As a representative example, it might be 60 feet from the top of the TCP assembly at 14 to the isolation tool 24 of the present disclosure. The requisite tubing joints are placed below the isolation means 24 and are filled with clean fluid to obtain a standing column of fluid retarding the velocity of the dropped detonating bar to a desired velocity. The fluid is clean and is also isolated, thereby assuring that invading well fluids do not change the viscosity or makeup of the standing column of fluids. In a typical situation, the tubing will range from about 23/8 inches in diameter and up. The present apparatus is installed in the tubing string at a desired location above the TCP assembly 14. Connections are made with conventional threaded pin and box connections well known for tubing strings.
Going now to the detailed view of the isolation tool 24 better shown in FIG. 2, its construction will be described from the top to the bottom. The numeral 30 identifies an upper end sub which has a mating threaded box 32 for makeup in the tubing string. The sub 30 has a specified length and terminates at a shoulder 34. Moreover, it threads to a sleeve 36 which is fixedly attached by means of a suitable set screw 38. The components not only thread together as illustrated, but they are also held against unthreading by positioning the set screw at the illustrated location. The sleeve 36 is of any suitable length and terminates at a pin connection 40 at the lower end to enable continuation of the tubing string. The pin connection is immediately adjacent to an enlarged or thickened wall portion 42 which defines a shoulder 44. This shoulder limits travel of components in the isolation tool which will be described.
The numeral 46 identifies the cylindrical interior wall of the sleeve. This serves as a guide and seal surface for a traveling assembly. This assembly is generally described as a floating piston assembly at 50. This assembly is formed by several components which move together. One of the components is a sleeve 52. It is axially hollow and is formed with a fluid drainage port at 54. Any fluid introduced into the tubing string thereabove will drain to the exterior through the port 54. The sleeve 52 is captured on the interior of the sleeve 36. The sleeve 36 has several long slots formed at 56. The sleeve 52 is threaded to a valve sleeve 58. The two components thread together capturing a frangible glass disk 60. The disk 60 is sized so that it is easily broken by the falling detonating bar 20. The disk 60 is sufficiently thick that is supports a standing of a column of fluid thereabove that in the event that fluid accumulates in the tubing string above the isolation tool 24. Leakage past the disk is prevented by securing the disk with suitable O-ring seals in facing grooves as illustrated in FIG. 2.
The valve sleeve 58 threads to another sleeve at 62. The sleeve 62 extends the length of the floating piston assembly, and cooperates with the valve sleeve 58 in a special fashion as will be described. The valve sleeve 58 terminates at a shoulder 64. The shoulder 75 supports on O-ring 66 riding on the shoulder. The O-ring is captured by its own resiliency and tends to shrink against the shoulder 75. It is confined by the abutting shoulder, thus fitting in a V-shaped groove. A fluid flow path is defined through ports or openings 70 below the O-ring 66, thereby forcing the O-ring 66 to expand. Fluid flows past the O-ring and along the shoulder 75 to escape through lots 76 from between the components 58 and 62. This fluid is then on the exterior of the floating piston assembly 50. It is voided through the slots 56 as shown in FIG. 2.
The piston assembly 50 travels upwardly and downwardly. It is guided by the elongate construction shown in FIG. 2. Suitable O-rings 72 and 74 prevent leakage below the piston assembly 50. The floating piston assembly 50 thus defines two flow paths from the interior of the balanced isolation assembly to the exterior. The large port 54 is located above the glass disk at 60. Any fluid which is in the tubing string above the isolation tool 24 drains to the port 54 and out through the slots 56. A second drainage path is included for the tubing string below the glass disk. This flow path is controlled by a check valve mechanism. The flow path includes the several holes 70. The check valve mechanism includes the O-ring 66 on the tapered surface 75. The flow path is from the interior to the exterior under control of the check valve. Flow in the opposite direction is not permitted by operation of the check valve O-ring 66.
Operation of this isolation tool 24 should be considered. Assume that it is installed in the tubing string and located in the well. Assume further that a measured standing column of clean fluid is located therebelow. The standing column of clean fluid is protected by this apparatus. Assume further that there is fluid in the tubing string above the isolation tool 24. In that instance, when the detonating bar 20 is dropped, it simply travels along the tubing string and ultimately arrives at the fluid above the isolation tool 24. The fluid above the isolation tool 24 will slow the bar 20 to cushion impact on the isolation tool 24. The detonating bar will strike and break the glass disk 60. Then, it falls through the standing column of clean fluid, having the desired retardation.
Consider the column of liquid above the disk 60. Assume that the fluid is quite different from the isolated clean fluid below the isolation tool. Excess fluid above the isolation tool is free to drain out through the port 54 assuming there is a pressure differential acting across the port 54. Whether some fluid drains or not, the dropped detonating bar will fall along the tubing string through fluid above to tool 24, strike the disk 60 and then fall in the column of clean fluid. Even when the bar 20 falls through heavy or viscous drilling fluid above the glass disk 60, the velocity of the dropped detonating bar is still sufficient to break the disk 60 and then fall at a desired velocity in the clean fluid such that the TCP assembly therebelow is properly operated.
The isolation tool 24 isolates two separate columns of fluid. The fluid below the isolation tool 24 is clean to obtain controlled bar velocity, and also has a fixed length to assure a desired terminal velocity. The isolation tool 24 separates the upper fluid column thereabove. The upper fluid column is included to slow down the bar 20 to limit impact damage at the tool 24. To illustrate, assume that the packer is located at a depth of 10,000 feet. Assume further that the isolation tool 24 is at 10,050 feet. Assume further that 60 feet of clean water is isolated between the tool 24 and the TCP detonating apparatus. If the bar 20 is dropped in open tubing, the velocity may well be in excess of 100 miles per hour at the impact with the glass disk; such a high velocity impact will destroy the disk and may well damage the bar 20. Therefore a column of standing fluid is placed above the disk to slow the projectile bar. As an example, the velocity can be slowed by 50 feet of relatively thick mud.
The dropped detonating bar 20 will impact the first fluid column (above the tool 24) and be slowed to some speed; in fact, any speed sufficient to break the glass disk will suffice. The velocity is retarded to limit impact damage. Then the bar 20 falls through the controlled viscosity fluid at a velocity regulated by the isolated column of fluid. This rate of fall is controlled or limited to a desired range. By contrast, the column of fluid above the isolation tool 24 can vary over a wide range in viscosity and fluid column height. Even though the upper column of fluid may vary widely, the isolated column does not vary (by virtue of its isolation) so much and hence the bar 20 velocity is regulated. This limits impact damage and yet assures adequate impact and detonation.
As a further possibility, the pressure on the outside of the tubing string may increase. The floating piston assembly is free to travel downwardly through a specified stroke, the stroke being determined by the spacing between the downwardly facing shoulder 77 and the upwardly facing shoulder 44 near the bottom of the isolation tool 24. The glass disk 60 is sufficiently thick to withstand some pressure differentials acting thereacross.
Assume however, that the pressure differential acting on the floating piston assembly 50 forces it upwardly. It is free to travel upwardly, but travel is limited by the shoulder 34. Pressure relief from below the floating piston assembly is obtained by the valve means incorporating the O-ring 66. This function as a check valve. When a suitable pressure differential acts across the device, fluid flows past the O-ring 66. The escape path for the fluid extends to the slots 56 formed in the surrounding sleeve. Because of this arrangement, the piston assembly 50 can travel downwardly to equalize pressure. Additionally, it can travel upwardly to equalize pressure. If travel upward to the shoulder at 34 limits further movement, the O-ring 66 functions as a check valve thereby venting pressure fluid to obtain pressure equalization.
In a typical installation, the travel of the traveling piston assembly is quite small compared to the height of the column of standing clean fluid therebelow. Thus, when the detonating bar is dropped, it can be known with certainty that the detonating bar velocity through the standing column of fluid is regulated. This assures proper operation of the detonating bar, particularly controlling the velocity and impact of the detonating bar on the TCP assembly. Moreover, the clean fluid is protected because it is isolated to avoid invasion by well fluids which might change of the nature of the column of fluid.
While the foregoing is directed to the preferred embodiment, the scope is determined by the claims which follow.
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In tubing conveyed perforating well completion operations, shaped charge detonation is achieved by dropping a detonating bar in the tubing string. Velocity of the detonating bar is controlled by placing a column of standing fluid above the tubing conveyed perforating assembly. This apparatus and method isolate a column of standing fluid. Moreover, invasion by a well fluid is prevented to assure that the retardation characteristics of the standing fluid are not changed by invading well fluids. The apparatus includes a tubing string pressure isolation piston assembly slidable within a sleeve and a frangible closure disk broken by the detonating bar; the isolation tool further includes check valve means controllably venting fluid pressure across the valve means.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 695,585, filed June 14, 1976, and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to automatic clothes washing machines and more particularly to an improved structure in such machines for effecting the washing of very small loads of clothing and especially delicate and synthetic fiber types of clothing.
Automatic clothes washing machines customarily provide, in a clothes basket adapted to hold several pounds of clothes, a sequence of operations in order to wash, rinse, and extract water from the clothes in the basket. The sequence ordinarily includes a water fill followed by a washing operation which, in a vertical axis type machine, is provided by an agitator movably arranged to oscillate back and forth within the basket; a first centrifugal liquid extraction operation in which the wash water is removed from the clothes by spinning the basket; another water fill followed by a rinsing operation in which the clothes in the basket are rinsed in clean water while the agitator is oscillated; and a final centrifugal liquid extraction operation in which the basket is spun to remove the rinse water from the clothes. Machines having this type of cycle, or a variation thereof, generally produce highly satisfactory results in that the clothes in the machine come out properly cleaned and with a substantialy part of the liquid removed.
As stated, in order to have an adequate capacity, the clothes containing basket must be large enough to accept several pounds of clothing generally in the range of eight to twelve pounds, and to contain them loosely enough so that a satisfactory washing effect will be obtained. Because of this prime factor, that of adequate clothes capacity, the clothes containing basket presents some disadvantages when a very small load of clothes is to be washed. This type of load may occur for various reasons, but in particular, it occurs with respect to delicate and dainty garments which are usually made from synthetic fibers or blends of synthetic and cotton fibers. These type garments should be washed by themselves and not with other heavier garments, and particularly with respect to clothes which are not colorfast, such as socks, jeans, etc. which would harm other clothing if washed with them.
One disadvantage which presents itself when very small loads are washed in the basket of a washing machine is that the amount of water required for washing a few small garments may be comparable to the amount of water used for washing several pounds of clothing. This, of course, represents an inefficient use of water with a resulting high cost of water and energy in heating the water in consideration of the result being obtained. Also, there is the corollary that the greater the quantity of water used, the greater quantity of detergent needed in order to effect a proper detergent concentration in the water, and this too represents an increased cost factor. Considerations such as these have quite often led the owners of domestic clothes washing machines to do the washing of small quantities of delicate garments by hand despite the availability of the machine.
One solution to this problem is the use of a small basket placed on the agitator inside the larger regular wash clothes basket. The motion of the agitator carries with it the small basket and provides a motion of the liquid in the basket which causes a suitable delicate type washing action. This type of washing machine is described in U.S. Pat. No. 3,014,358 and is assigned to the assignee of the present invention. In the use of a small wash basket as described in U.S. Pat. No. 3,014,358, the clothes within the small basket are subjected to the same operational cycles as when the machine is used with a "normal" operation, that is, when the clothes are in the large basket and includes a water fill followed by a bath type washing operation. A bath type washing action is when the clothes are submerged in water that nearly fills the small wash basket. After the washing operation there is a first centrifugal liquid extraction operation in which the wash water is removed by spinning the basket. There is then another water fill followed by a rinsing operation wherein clean fresh water is introduced into the basket and agitated and then followed by a final centrifugal liquid extraction operation by spinning the basket again. The disadvantages in such a clothes washer and method of washing clothes is brought about particularly by the use of synthetic fibers in today's garments. There is a tendency during the spin or liquid extraction operation for the clothes to become compacted by the centrifugal force and wrinkling is induced. The wrinkling is more likely to occur when the water is warm and it has been found to be advantageous to gradually reduce the temperature of the water before the centrifugal liquid extraction operation. In addition, it is highly desirable to reduce the amount of water used in the washing and rinsing operations as compared to bath type operations, yet maintain the good washing characteristics of the machine and method.
By my invention I have improved the prior art washing machine. The amount of water used is reduced by utilizing a flow-through wash and rinse operation where the clothes are only sopping wet as compared to bath type operations which in turn results in less detergent being needed for the washing operation.
SUMMARY OF THE INVENTION
There is provided in a vertical axis clothes washing machine having wash, rinse, and spin extraction operations including a tub, an agitator, a first basket within the tub, a second basket disposed within the first basket and positioned on the agitator for movement therewith, water supply means feeding hot and cold water into the machine, electrically powered drive means for operating the agitator to effect washing of the fabrics and for rotating the baskets to centrifugally extract water from the fabrics, communication means to allow water to flow from the baskets into the tub, recirculating means arranged to take water from the tub and recirculate it into the baskets during the wash and rinse operations, an improved clothes washing machine and method. The improvement comprises incorporating into the clothes washing machine described above a separate cycle of a continuous wash and rinse operation followed by a spin extraction operation for washing clothes in only the second basket and includes means to continuously introduce fresh water into the second basket during the combined wash and rinse operation and diverting means in the recirculation means to continuously direct water to drain during the continuous wash and rinse operation. There is also provided means to stop the flow of fresh water into the second basket at the end of the combined wash and rinse operation after which a spin extraction operation follows and water is taken from the tub and directed to drain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front elevational view of a clothes washing machine incorporating my invention, the view being partly broken away and partly in section.
FIG. 2 is a schematic diagram of an electric control circuit that may be used with my invention in the machine in FIG. 1.
FIG. 3 is a schematic view of the cam surfaces used in the control of the timer operated switches of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, and initially to FIG. 1 thereof, there is illustrated an agitator-type vertical-axis automatic clothes washer 10 having a supporting structure or load member 11. The washer may include the various operational components conventionally utilized in a domestic automatic washing machine, for instance, an imperforate tub 12 rigidly mounted within structure 11. Rotatably supported within tub 12 is a perforate washing basket 13 having openings 10 for washing and rinsing clothes therein and for centrifugally extracting liquid therefrom. At the center of basket 13 there is provided an agitator 14 which includes a center post 15 having a plurality of water or liquid circulating vanes 16 joined at their lower end to form an outwardly flared skirt 17.
Both the clothes basket 13 and the agitator 14 are rotatably mounted. The basket 13 is mounted on a hub 19 and the agitator 14 is mounted on a shaft 20 which extends upwardly through the hub 19 and through the center post 15 and is secured to the agitator so as to drive it. During one possible cycle of operation of the washer 10, fabrics, detergent and a predetermined quantity of liquid are introduced into the tub 12 and basket 13, and the agitator is then oscillated back and forth about its axis to move the clothes within the basket. After a predetermined period of this washing action, the agitator and basket 13 are rotated in unison at high speed to centrifugally extract the washing liquid from the fabrics and discharge it to a drain (not shown). Following this extraction operation, a supply of clean fresh liquid is introduced into the basket for rinsing the fabrics and the agitator is again oscillated. Finally, the agitator and basket are once more rotated in unison at high speed to extract the rinse liquid.
Also secured on the agitator 14 so as to move therewith is a clothes containing basket 18 which is small relative to basket 13 and tub 12. Basket 18 has a plurality of openings 9 in the side wall and particularly at the bottom and one or more conventional very small opening 9a in the bottom wall for removal of heavy soil. The openings 9 are to provide for flowing water through the basket 18 so that the basket does not fill. Thus a flow through washing and rinsing action is provided and not a bath type washing and rinsing action. This aspect will be described in more detail later. The lower inner portion of the annular basket 18 may be formed as shown at 8 to accommodate the tops of the vanes 16 of the agitator and acts to position the basket securely on the top of the agitator so that there will not be any relative rotation of the two.
Completing the description of basket 18, it is preferably provided with suitable fins or vanes 7 on the inner surface of the outer wall, which vanes are formed so as to effect a washing movement of the clothes within the basket 18 in response to the movement of the basket which is provided to it by its association with the agitator 14.
The small basket 18 is preferably removably positioned on agitator 14 so that it may be removed when so desired and readily replaced on the agitator and secured thereto so as to move therewith.
The basket 13 and agitator 14 may be driven by any suitable means. By way of example, I have shown them as driven by a reversible motor 21 through a drive mechanism including a clutch 22 mounted on the motor shaft. The motor is tailored so as to be used to its full extent when it accelerates the basket 13 to spin speed. In order to assist the motor during starting, clutch 22 allows the motor to start with less than a full load and then accept the full load as it comes up to speed. A suitable belt 23 transmits power from clutch 22 to a transmission assembly 24 through a pulley 25. Thus, depending upon the direction of motor rotation, the pulley 25 of transmission 24 is driven in opposite directions. The transmission 24 is so arranged that it supports and drives both the agitator drive shaft 20 and the basket mounting hub 19. When motor 21 is rotated in one direction, the transmission causes agitator 14 to oscillate and when motor 21 is driven in the opposite direction, the transmission causes the clothes basket 13 and agitator 14 to rotate together at high speed for centrifugal fluid extraction.
In addition to operating the transmission 24 as described, motor 21 also provides a direct drive through flexible coupling 26 to a pump structure 27, which includes two separate pumping units 28 and 29 which are operated simultaneously in the same direction by motor 21. Pump unit 29 has an inlet connected to the tub 12 and an outlet connection by a conduit 32 to a suitable external drain (not shown). Pump 28 has an inlet connected by a conduit 33 to the interior of tub 12 and an outlet connected by conduit 34 to a nozzle 35 which is positioned to discharge into the basket 13. Located between the nozzle 35 and pump unit 28 is a liquid diverter assembly 30 for alternatively directing the liquid flow to conduit 31 that is connected to conduit 32 for discharge to an external drain. The purpose of the flow diverting arrangement will be discussed later. With this structure, then, the "normal operation" of the washer, that is, when clothes are washed in the large outer basket 13, when the motor 21 is operating so as to provide the washing mode or agitation, pump unit 28 draws liquid in from tub 12 and discharges it through conduit 34 into the basket 13. Conversely, when the motor is reversed so as to rotate the basket 13 and agitator 14 together at high speed to centrifugally extract fluid from fabrics in the basket, pump unit 29 will draw liquid from the tub and discharge it through conduit 32 to drain. Each of the pump units is substantially inoperative in the direction of rotation in which it is not used.
Hot and cold water may be applied to the machine through conduits 42 and 43 which are adapted to be connected respectively to sources of hot and cold water (not shown). Conduits 42 and 43 extend into a conventional mixing valve structure 44 having solenoids 45 and 46 and being connected to a nozzle 47. In a conventional manner selective or concurrent energization of solenoids 45 and 46 will provide passage of hot, cold or warm water from the mixing valve 44 through the nozzle 47. Nozzle 47 is positioned to discharge into the basket 18 so that when one or both of solenoids 45 and 46 are energized, water enters the machine.
Connected to the hot and cold water conduits 42 and 43 is another conventional mixing valve structure 48 having solenoids 50 and 52 and being connected to the nozzle 47. This mixing valve 48 is utilized, as will be discussed later, in connection with the improved washing cycle for delicate and synthetic garments being washed in the small basket 18.
Completing now the description of the electrical control system for the machine of FIG. 1, reference is made to FIG. 2. At the heart of this control system is a sequence control assembly designated generally in FIG. 1 by the numeral 85 having a dial 86. Forming a part of the sequence control assembly 85 is a timer motor 87 which drives a plurality of cams 88, 89, 90 and 91. These cams, during their rotation by the timer motor, actuate various switches (as will be described), causing the machine to pass through the cycle of operations which includes washing, spinning, rinsing and spinning.
It will be understood that present day washers often include various improvements such as control panel lights, etc., which do not relate to the present invention and have been omitted for the sake of simplicity and ease of understanding.
The electric circuit, as shown in FIG. 2, as a whole is energized from a power supply (not shown), through a pair of conductors 92 and 93. Cam 88 controls a switch 94 which includes contacts 95, 96 and 97; when the cam has assumed the position where all three contacts are separated, washer 10 is disconnected from the power source and is inoperative. When operation of washer 10 is to be initiated for a "normal" operation, that is, when clothes are to be washed in basket 13 and basket 18 has been removed from the machine, switch 94 is controlled by cam 88 so that contacts 95 and 96 are engaged. Switch arm 54 is controlled by cam 56 and would take a position against contact 58. When a main switch 98 is closed (by any suitable manual control, not shown), power is then provided to the control circuit of the machine from conductor 92 through contacts 95 and 96. From contact 96, the circuit extends through a conductor 99, switch arm 54, contact 58, and a manually operated switch 100 to the valve solenoid 45. In addition, a circuit is completed from conductor 99 through a switch 101 controlled by cam 89. During the "normal" operation of the washer, cam 89 would cause switch 101 to close and make electrical connection with contact 59. In the "up" position, switch 101 completes a circuit through contact 57 for solenoid 45 independently of switch 100; in the "down" position shown, the switch 101 through contact 59 completes a circuit for solenoid 46. Thus, when switch 100 is open, energization of solenoids 45 and 46 is under the control of switch 101, but when switch 100 is closed the cold water solenoid 45 may be energized independently of the position of switch 101. From the hot and cold water solenoids, the energizing circuit then extends through a conductor 102 and then to a coil 103 of a relay 104, the main or run winding 105 of motor 21, a conventional motor protector 106, a switch 107 controlled by cam 91, and the conductor 93.
Motor 21 is of the conventional induction type which is provided with a start winding 108 which assists the main winding 105 during starting of the motor and is energized in parallel therewith. When a relatively high current passes through the relay coil 103, it causes the normally open switch 109 to close; this permits an energizing circuit for the start winding to be completed in parallel with the main winding through a contact 110 of the switch generally indicated at 111 and which is controlled by cam 90, contact arm 112, the relay contact 109, the start winding 108, a contact arm 113, and the contact 114 of switch 111. A circuit is also completed in parallel with motor 21 through the timer motor 87. Relay 104 is designed to close switch 109 when a relatively high current, of the level demanded by the motor when the motor is rotating below a predetermined speed, is passing through it. At other times when there is no current passing through the relay coil 103, or when the current is below the required energizing level as is true in the running speed range of the motor, the switch 109 is open.
When the main winding 105 of motor 21 is in series with valve solenoids 45 and 46, as described, a much lower impedance is presented in the circuit by the motor 21 than is presented by the valve solenoids. As a result, the greater portion of the supply voltage is taken up across the solenoids and relatively little across the motor. This causes whichever of the solenoids is connected in the circuit to be energized sufficiently to open its associated water valve. As a result, water at a selected temperature is admitted to the machine through hose 47, motors 21 and 87 remaining inactive.
This action continues, with the circuitry thus arranged, so that water is admitted to basket 13 and tub 12. Because of the perforations in basket 13, the water rises in both basket 13 and tub 12 at the same rate. Water level control switch 77 is connected across conductors 99 and 102 as shown, so that when switch 77 closes, it excludes the solenoids 45 and 46 from the effective circuit by short circuiting them. As a result, the soleniods become de-energized and a high potential drop is provided across winding 105 of motor 21. This causes the relay 104 to close contact 109 to start the motor 21 while, at the same time, timing motor 87 starts so as to initiate the sequence of operations. It will be observed that the energization of the valve solenoids 45 and 46 on the one hand, and the energization of the drive motor 21 on the other hand are alternative in nature. In other words, when there is sufficient potential across the valve solenoids to energize them, the motor remains de-energized, and it is necessary to short the solenoids out of the circuit so that they are de-energized before the drive motor can be energized.
The switch 107 is in series with the main motor 21 but is not in series with the timer motor 87. Thus, by the opening of switch 107, the energization of motor 21 may be stopped. The timer motor will continue to operate though, as a result of the fact that the timer motor 87 is deliberately provided with an impedance much greater than that of the valve solenoids so that it will take up most of the supplied voltage and the solenoids, therefore do not operate their respective valves.
A further point of the circuit of FIG. 2 is that when switch arms 112 and 113 are moved by cam 90 to engage contact 114 and a contact 115 respectively, the polarity of the start winding is reversed. The circuit from conductor 102 then proceeds through contact 115, contact arm 113 to start winding 108, relay contact 109, contact arm 112 and contact 114 to the switch 98 and conductor 93. Thus, provided motor 21 is stopped or slowed down so that relay contact 109 is closed, the reversal of switch 111 is effective to cause the motor 21 to rotate in the opposite direction when the motor is started up again.
In order to energize motor 21 independently of the water level switch 77 and the valve solenoid, so that a spin operation may be provided without regard to the absence of the predetermined water level, cam 88 is formed so that it may close all three contacts 95, 96, and 97 of switch 94 during the centrifugal liquid extraction operation. When this occurs, it causes the power to be supplied from conductor 92 directly through contact 97 to conductor 102 and the motor rather than through the water level switch or the valve solenoids.
Referring now to FIG. 3 in conjunction with FIGS. 1 and 2, a sequence of operations of the washer 10 will be described during "normal" operation wherein clothes are washed in basket 13 and basket 18 has been removed from the machine. It will be assumed that the timer has been set at the beginning of the wash step so that cam 88 has caused contacts 95 and 96 to be closed, cam 56 caused contact arm 54 to connect with contact 58, cam 89 has caused contact 101 to move to its "down" position and connect with contact 59, cam 90 has positioned 111 as shown, and cam 91 has closed switch 107. At this point, with main switch 98 closed, the first step which takes place, because of the aforementioned impedance relationship, is the filling of the machine with water by the energization either of the solenoid 46 alone to provide hot water or else, if switch 100 has been manually closed, by the energization of solenoids 45 and 46 together to cause warm water to be supplied to the machine. The energization of the solenoids 45 and 46 causes motors 21 and 87 to remain inactive until the closure of switch 77 at a predetermined liquid level.
At this point, the solenoids 45 and 46 are de-energized and, consequently, motors 21 and 87 are energized. The energization of motor 21 is in the direction to cause agitator operation (because of switch 111) and to provide a recirculation action by pump 28, drawing water from the tub through inlet conduit 33 and then discharging it back into the tub through outlet conduit 34. This action, which conventionally is called the washing operation or wash mode, continues for a predetermined time until pause A is reached, at which time cam 91 opens switch 107. This stops the operation of motor 21 and, consequently, there is no further agitation although, as explained, the timer motor 87 continues to operate. During pause A, cam 88 closes all three contacts 95, 96 and 97 of switch 94 together to connect conductor 102 entirely independently of water level switch 77 and so as to exclude the valve solenoids 45 and 46. Also at this time cam 90 reverses the position of switch 111. The reversal of switch 111 reverses the polarity of start winding 108 relative to main winding 105. As a result, when switch 107 is re-closed by cam 91, motor 21 is energized once again but in the opposite direction. This is the end of pause A. The motor 21 is then driving the pump 29. The energization of the motor 21 and the de-energization of the valve solenoids result from the fact that the valve solenoids are bypassed by the new condition of switch 94. As a result of the opposite rotation of motor 21 from that of the wash mode, the motor causes a spin operation and simultaneously operates the pump 29. The pump 28 is ineffective during this operation, tending to draw in fluid through conduit 34 and expel it through conduit 33.
The spin operation is provided at a relatively high speed of rotation of the basket which may, for instance, be on the order of 600 RPM so as to extract a very substantial part of the liquid from the clothes and have it removed by the pump 29. The spin operation continues until pause B, as shown in FIG. 3, at which time switch 107 is again opened by cam 91 to de-energize motor 21. At this time, cam 88 returns switch 94 to the same position that it had for wash. In addition, it is conventional at this time to change the position of switch 101 to its "up" position so that the cold water solenoid is energized. Switch 94 also returns to the same position that it had for wash, with the contact 97 disengaged from the other two contacts, and the motor connections are reversed to provide agitation rather than spin action. Thus, when pause B is terminated by the reclosing of the switch 107 to cam 91, water enters the basket until the switch 77 is tripped, and then an agitation step proceeds in the same manner as the wash step, that is, by the shorting out of the valve solenoid by switch 77.
After a suitable rinsing period, another pause, designated C, is provided and also has a drain period followed by another spin operation performed in the same manner as before, after which cam 88 opens all three contacts of switch 94 to terminate the operation completely by de-energizing all components of the system.
It should be noted that while the use of a relay 104 is shown and described in the preferred embodiment above, a motor having a centrifugal switch for controlling the start winding may be used in place of the relay 104 and accomplish the same desirable function. Therefore, the function of relay 104 and the function of a centrifugal switch that controls the start winding of the motor are equivalent in operative effect.
The foregoing description of the clothes washing machine operation is the "normal" operation where clothes are washed in the basket 13 by oscillating the agitator back and forth while the wash water is recirculated to the basket 13. This is the prior art machine operation. By my invention I incorporate into that type of machine a separate combined continuous clothes washing and rinsing cycle. It may be selected by the machine operator by programming the controls as by selecting a portion of the dial 86 that automatically programs the cycle. This separate continuous washing and rinsing cycle is used to wash and rinse garments usually made of synthetic fibers, or blends of synthetic and cotton fibers, and the garments are washed and rinsed only in the small basket 18 with a fresh water flow-through system and not a bath type washing and rinsing action where the garments are submerged in the water. That is, the water used in the washing and rinsing operation does not fill the basket but rather is only enough to saturate the garments so that they are sopping wet and it also is not recirculated back into the basket but is pumped to an external drain. The fresh water introduced into the basket 18 is at a substantially reduced flow rate relative to the "normal" wash operation, and the wash and rinse operations are continuous with no centrifugal extraction operation until after the continuous wash and rinse operation. The wash and rinse water is flowed through the second basket 18 into the first basket 13 at a rate sufficient to prevent a bath type washing action in the second basket. The rate of water flow through the second basket 18 after the clothes become saturated would be at least equal to the rate of fresh water being introduced into the second basket 18. During the continuous wash and rinse operation, preferably, the temperature of the water in the basket 18 and therefore the garments, is gradually reduced. It has been found that by gradually reducing the temperature of clothes made of synthetic fibers their tendency to wrinkle is reduced. This is accomplished by stopping the flow of hot water part way through the continuous wash and rinse operation while either continuing the flow of cold water or starting the flow of cold water. The latter would be the case where the cycle was programmed to initially introduce only hot water as opposed to warm water where both hot and cold water is mixed to give a warm water wash. When the wash and rinse operation is completed agitation and water flow is stopped and a spin centrifugal extraction operation completes the cycle. At the time of spin the temperature of the clothes has been reduced so the tendency of them to wrinkle during spin is reduced.
With reference to FIG. 2, the electric circuit of the improved clothes washer and method of washing clothes will be described. FIG. 2 is shown in condition for the washer to implement the small load cycle that is incorporated into a conventional clothes washer. On this setting cam 88 closes switch 94 so the contacts 95 and 96 are engaged. Cam 56 causes switch 54 to be closed and connect with contact 60. Main switch 98 is closed (by any suitable manual control, not shown), so that power is then provided to the control circuit of the machine from conductor 92 through contacts 95 and 96 to contact 60.
From contact 60, the circuit extends through a conductor 61 to switches 62, 63, and 64, all of which are closed by respective cams 65, 66, and 67. Closing switch 62 causes the agitator 14 carrying the small basket 18 to oscillate back and forth as described heretofore in connection with operation of the machine utilizing "normal" wash and rinse operations. Switch 63 causes valve solenoid 50 to be energized and open its associated water valve, which in this case is the hot water. Solenoid 52 is also energized and causes its associated cold water valve to open resulting in both the hot and cold water flowing through the mixing valve 48 and exiting nozzle 47 into the small basket 18. With switch 64 closed by cam 67 a solenoid 68 is energized causing diverter 30 to divert the water into conduit 31 where it is pumped to an external drain and not recirculated through conduit 34 as was the case in connection with operation of the clothes washer during the "normal" operation.
It is highly desirable to have the water valves arranged to provide a much lower flow of water into basket 18 than was the case in connection with the "normal" clothes load operation of the machine through the mixing valve 44. Generally speaking, the "normal" operation of the machine requires about four gallons per minute for each of the hot and cold valves. In the case of the small wash load cycle, the water flow rate is between a quarter of a gallon and a gallon of water per minute total for both valves. The water is removed from the second basket 18 after the clothes become saturated at least at this rate by means of the openings being of sufficient number and size to prevent a bath type washing and rinsing action.
As can be seen particularly in FIG. 3, part way through the continuous wash and rinse operation, cam 66 opens switch 63 to de-energize solenoid 50 and close the hot water valve. The cold water valve will remain open through the rest of that cycle until reaching pause D. By this arrangement, the wash water temperature is gradually reduced from warm to cold before the clothes in the small basket 18 are subjected to a spin operation, which could normally induce wrinkling.
After the continuous wash and rinse operation the spin operation is conducted in the same manner as in connection with the "normal" washing operation and cams 56, 66, 65, and 67 cause their respective associated switches to be opened while the basket 18 is spinning to effect centrifugal extraction of water from the now cooled garments contained in the small basket 18. During the spin operation the pump unit 29 is operating to expel liquid from the tub to an external drain. At the end of the spin cycle operation, cam 88 causes switch 94 to open and terminate operation of the machine.
The foregoing is a description of the preferred embodiment of the invention, and it is to be understood that variations may be made thereto without departing from the true spirit of the invention, as defined by the appended claims.
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An improved vertical axis clothes washing machine and method having wash, rinse, and spin extraction operations including a tub, an agitator, a first basket within the tub, a second basket disposed within the first basket and positioned on the agitator for movement therewith. There is also a water supply for feeding hot and cold water into the machine, electrically powered drive for operating the agitator to effect washing of the fabrics and for rotating the baskets to centrifugally extract water from the fabrics. Water is allowed to flow from the baskets into the tub and may be recirculated from the tub into the baskets during the wash and rinse operations. The improvement is a separate cycle of a continuous wash and rinse operation followed by a spin extraction operation for washing clothes in only the second basket while fresh water is introduced continuously into the second basket during the combined wash and rinse operation and directed to drain and not recirculated. At the end of the continuous wash and rinse operation the fresh water flow is stopped and a centrifugal extraction operation is completed. The improved machine and method minimizes the amount of water used, reduces the temperature of the water and clothes to minimize wrinkling during the spin operation, improves the removal of oily soil responsive to detergent concentration, and provides for the removal of "removed" soil from the basket which minimizes redeposition.
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FIELD OF THE INVENTION
[0001] This invention relates to a wireline valve and particularly but not exclusively to an actuator assembly for a wireline valve used to seal off wirelines, measuring or slick lines and deployment bars as used in the oil and gas industry. These wireline valves are commonly known in the industry as wireline Blow-Out Preventors (BOPs).
BACKGROUND OF THE INVENTION
[0002] Wireline BOPs are provided for oil and gas wells in order to seal off the wellbore. Typically, wireline BOPs comprise one or more pairs of actuators which are hydraulically activated to close the well, resisting the well fluids and thereby preventing well blow-out. The rams are then locked in position by a secondary means which may comprise a threaded stem or a tapered wedge.
SUMMARY OF THE INVENTION
[0003] According to a first aspect of the present invention there is provided an apparatus capable of resisting the flow of fluids through a bore, the apparatus including at least one actuator assembly, the or each actuator assembly having a first and second end and being adapted to move between a first configuration wherein fluids are permitted to flow through the bore, and a second configuration wherein fluids are resisted from flowing through the bore, wherein the first and second ends are each exposed to the pressure in the bore; the apparatus further comprising a biasing arrangement adapted to bias the actuator assembly toward one of the first and second configurations.
[0004] Preferably, the biasing arrangement comprises a piston with a first end and a second end, each end being sealed within a cylinder by first and second sealing mechanisms, and wherein the first sealing mechanism provides a smaller cross sectional sealing area than the second sealing means.
[0005] According to a second aspect of the present invention there is provided an apparatus capable of resisting the flow of fluids through a bore, the apparatus including at least one actuator assembly, the or each actuator assembly having a first and second end and being adapted to move between a first configuration wherein fluids are permitted to flow through the bore, and a second configuration wherein fluids are resisted from flowing through the bore, wherein the first and second ends are each exposed to the pressure in the bore and wherein a locking member is provided to abut with the actuator assembly when it is in the second configuration in order to resist movement of the actuator assembly from the second configuration to the first configuration.
[0006] Preferably, the locking member is threadably engaged on a cylinder.
[0007] Preferably, the cylinder is of varying diameter. Typically, the locking member is provided on a portion of the cylinder which is smaller in diameter than the portion of the cylinder from which rods extend.
[0008] Preferably, a sleeve is threadably mounted on the locking member and can be rotated in a first direction to engage a further portion of the cylinder or in a second direction to cause movement of the locking member toward the actuator assembly.
[0009] Preferably, the locking member has an internal thread and an external thread, said internal thread being oppositely directed to said external thread.
[0010] According to a third aspect of the invention, there is provided an apparatus capable of resisting the flow of fluids through a bore, the apparatus including at least one actuator assembly, the or each actuator assembly having a first and second end and being adapted to move between a first configuration wherein fluids are permitted to flow through the bore, and a second configuration wherein fluids are resisted from flowing through the bore, wherein the first and second ends are each exposed to the pressure in the bore and wherein the actuator assembly comprises at least one rod which extends from the actuator assembly to a position in which it is visible from an outside of the apparatus.
[0011] This aspect of the invention has the advantage that the outwardly visible rod demonstrates to an operator the degree of movement of the actuator assembly between the first and second configuration.
[0012] Preferably, there are a plurality of rods such as three rods. Preferably, the rods extend through apertures provided in the cylinder.
[0013] Preferably, a first end of the or each rod is attached to the actuator assembly and a second end of the or each rod is adapted to abut with a locking member such as the locking member of the second aspect of the invention.
[0014] Preferably, the or each actuator assembly is provided in a cylinder, and the cylinder comprises a hydraulic fluid chamber and a bore pressure chamber.
[0015] Preferably, the pressure in the bore and the pressure in the bore pressure chamber are equal.
[0016] Preferably, the actuator assembly comprises first and second hydraulic fluid chambers, wherein hydraulic fluid may be injected into either one of the first and second hydraulic fluid chambers to move the actuator assembly from the second configuration to the first configuration or from the first configuration to the second configuration respectively.
[0017] Preferably, the actuator assembly comprises a piston and a flange extends radially from the piston to separate the first and second hydraulic fluid chambers.
[0018] Typically, hydraulic fluid pressure may act on a first face of the flange, and may act on a second opposite face of the flange. The cross-sectioned area of the first and second faces of the flange upon which the pressure of the bore can act may be the same or may differ.
[0019] Preferably, the or each actuator assembly comprises a throughbore closure device provided at its first end.
[0020] Preferably, a channel is provided in the or each actuator assembly so that the bore is in fluid communication with the bore pressure chamber. More preferably, the channel extends through the piston.
[0021] Preferably, the or each actuator assembly is hydraulically activated.
[0022] To activate the or each actuator assembly, hydraulic fluid is typically injected into the hydraulic fluid chamber on one side of the flange and acts upon the flange of the piston to push the or each actuator assembly from the open configuration to the closed configuration.
[0023] Preferably, the locking member is then moved, typically by rotation, towards and the bore until further movement is resisted by the locking member abutting against the rod(s). This typically provides the secondary means to hold the actuator assembly in the closed configuration.
[0024] Preferably, the or each actuator assembly may also be moved from the closed configuration to the open configuration. To achieve this, the locking member is preferably moved, typically by rotation, in the opposite direction thereby disengaging the rods from the locking member. Preferably, hydraulic fluid is then injected into the first hydraulic fluid chamber typically provided on the opposite side of the flange of the piston. The hydraulic fluid typically acts on the opposite side of the flange in so doing moving the or each actuator assembly from the closed configuration to the open configuration.
[0025] Preferably, the sleeve is moved in order to activate the locking member to secure the actuator assembly in the second configuration.
[0026] Preferably, the sleeve may engage a portion of the cylinder in order to cover and/or protect the rods extending through the apertures of the cylinder. This is normally only necessary during transit of the apparatus.
[0027] Preferably, the apparatus comprises a pair of actuator assemblies adapted to engage with each other to resist flow of fluid through the wellbore when in their closed configuration. Optionally, there may be two or more pairs of actuator assemblies in order to resist flow of fluid through the wellbore at two distinct points.
[0028] According to a fourth aspect of the present invention there is provided an apparatus capable of resisting the flow of fluids through a bore, the apparatus including at least one actuator assembly, the or each actuator assembly having a first and second end and being adapted to move between a first configuration wherein fluids are permitted to flow through the bore, and a second configuration wherein fluids are resisted from flowing through the bore, wherein pressure in the bore is exposed to the first end of the actuator assembly and characterised in that a mechanism is provided to vary the pressure at the second end of the actuator assembly.
[0029] Typically, the mechanism is provided to vary the pressure balance at the second end of the actuator assembly with respect to the first end of the actuator assembly.
[0030] According to a fifth aspect of the present invention there is provided an actuator assembly for use with an apparatus capable of resisting the flow of fluids through a bore, the actuator assembly having a channel extending from a first to a second end.
[0031] Preferably, the actuator assembly is the actuator assembly used with the apparatus according to the any previous aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] An embodiment of the invention will now be described by way of example only with reference to the accompanying drawings wherein:
[0033] [0033]FIG. 1 is a sectional view of a wireline blow-out preventor (wireline BOP), in a closed configuration, according to the present invention;
[0034] [0034]FIG. 2 is a perspective view of the wireline BOP of FIG. 1;
[0035] [0035]FIG. 3 is an enlarged cross-sectional view of an arm of the wireline BOP of FIG. 1;
[0036] [0036]FIG. 4 is a perspective view of an actuator assembly (with ram body seals and cylinder omitted) of the wireline BOP of FIG. 1;
[0037] [0037]FIG. 5 is an exploded view of the actuator assembly of the wireline BOP of FIG. 1;
[0038] [0038]FIG. 6 is a sectional view of the wireline BOP of FIG. 1, in an open configuration;
[0039] [0039]FIG. 7 is a top view of the actuator assembly of FIG. 3;
[0040] [0040]FIG. 8 is a perspective view of the actuator assembly of FIG. 3;
[0041] [0041]FIG. 9( a ) is a side view of the cylinder of FIG. 3;
[0042] [0042]FIG. 9( b ) is a first cross-sectional view of the cylinder of FIG. 9( a ) through section A-A;
[0043] [0043]FIG. 9( c ) is a second cross-sectional view of the cylinder of FIG. 9( d ) through section C-C;
[0044] [0044]FIG. 9( d ) is an inner end view of the cylinder of FIG. 9( a ); and
[0045] [0045]FIG. 9( e ) is a cross-sectional view of the cylinder of FIG. 9( a ) through section B-B.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0046] [0046]FIG. 1 shows a wireline BOP 1 as comprising four arms 8 , 9 , 10 , 11 and a body 2 comprising a vertically arranged throughbore 3 . The wireline BOP 1 is normally placed at a wellhead (not shown) and can be activated to resist blow out of the well, as described below.
[0047] In each arm 8 - 11 there is provided an actuator assembly including rams 5861 in accordance with the present invention. The rams 58 , 59 of the arms 8 , 9 are provided opposite each other and are adapted to move from an open configuration as shown in FIG. 6 to a closed configuration as shown in FIG. 1, insodoing engaging each other and closing the throughbore 3 of the body 2 . Normally, a small aperture 4 is provided in the rams 58 , 59 in order to allow a wireline (not shown) extending through the bore 3 to remain in place and be largely unaffected by the closure of the rams 58 , 59 . Seals (not shown) are provided on the rams 58 - 61 in order to seal around the wireline and also to seal the wellbore.
[0048] The rams 60 , 61 of the arms 10 , 11 operate as described above for the rams 58 , 59 . Therefore the bore 3 is sealed by two pairs of rams 58 & 59 , 60 & 61 , the pairs operating independently of each other. Moreover, the features and operations of each actuator assembly are common to all and are hereafter described with reference to the actuator assembly provided in the second arm 9 and best shown in FIG. 3.
[0049] The actuator assembly of the second arm 9 includes the ram 59 which is supported by a guide 16 . The rearmost face of the ram 59 is attached to the forward end of a piston 6 which extends through a first bore or chamber 14 of a cylinder 12 into a second bore 42 of a housing 40 . The first bore 14 can be considered as a hydraulic fluid chamber 14 , and the second bore 42 can be considered as a wellbore pressure chamber 42 .
[0050] A first piston flange 50 extends radially outwardly from the piston 6 into hydraulic fluid chamber 14 , to support the piston 6 in the bore 14 of the cylinder 12 , and with the aid of an ‘O’ ring seal 52 , seals the piston flange 50 with respect to the inner surface of the cylinder 12 .
[0051] A second, smaller diameter piston flange 51 also extends radially outwardly from the piston 6 , where the smaller flange 51 is spaced apart from the first piston flange 50 along the main longitudinal axis of the piston 6 . Lip portions 32 of rods 33 are located in the gap between, and secured between the flanges 50 , 51 of the piston 6 . The rods 33 extend parallel to the main longitudinal axis of the piston 6 through apertures 49 (shown only in FIGS. 4 and 5) formed in an end cap 13 which is integral with the housing 40 . An ‘O’ ring seal 39 seals the bore of the aperture 49 with respect to the outer surface of the rods 33 . The outer most end of the rods 33 can abut against a piston lock ring 34 which is threaded to the housing 40 .
[0052] A channel or bore 54 extends through the piston 6 along the main longitudinal axis of the piston 6 , such that it extends from the throughbore 3 to the bore 42 of the housing 40 . The pressure in the bore 42 of the housing 40 is therefore equalised with the pressure in the throughbore 3 . Thus, significantly less force is required to move the piston 6 and associated ram 59 from the open to the closed configuration in order to close the throughbore 3 than would be required if the pressure in the throughbore 3 was greater than that in the bore 42 of the housing 40 , as is normally the case.
[0053] A first hydraulic line quick connect coupling 65 having an inner bore is provided on the outer surface of the cylinder 12 , where the inner bore of the coupling 65 is in fluid communication with an access port 66 provided in the sidewall of the cylinder 12 toward the outer most end thereof. A pressurised hydraulic line (not shown) is attached to coupling 65 in use, and in this manner pressurised hydraulic fluid can be injected through the access port 66 into the area of the hydraulic fluid chamber 14 between ‘O’ ring seal 52 , ‘O’ ring seal 44 and ‘O’ ring seals 39 .
[0054] A second hydraulic line quick connect coupling 67 having an inner bore is provided on the outer surface of the cylinder 12 , where the inner bore of the coupling 67 is in fluid communication with an access port 68 provided in the sidewall of the cylinder 12 toward the inner most in use end thereof. A pressurised hydraulic line (not shown) is attached to coupling 67 in use, and pressurised hydraulic fluid can be injected through the access port 68 into the area of the hydraulic fluid chamber 14 between ‘O’ ring seal 29 (shown in FIG. 3 as sealing the inner bore of the cylinder 12 with respect to the piston 6 ) and ‘O’ ring seal 52 provided on the main piston flange 50 .
[0055] An ‘O’ ring seal pack 45 seals the wellbore pressure within the well bore pressure chamber 42 from escaping into the first bore 14 . A first vent channel 43 is optionally provided through the sidewall of the end cap 13 between the ‘O’ ring seal 44 and the ‘O’ ring seal pack 45 , and serves to vent the wellbore pressure to atmosphere in the unlikely event that the ‘O’ ring seal pack 45 fails. A second vent channel 46 (shown on FIG. 9( b )) is optionally provided through the sidewall of the cylinder 12 between the ‘O’ ring seal 29 and an ‘O’ ring seal pack 47 (the inner most end of which sees wellbore pressure), and the second vent channel 46 also serves to vent the wellbore pressure to atmosphere in the unlikely event that the double ‘O’ ring seal 47 fails. In this manner, the wellbore pressure cannot pass into the hydraulic fluid chamber 14 , and so cannot be transmitted back down the first or second hydraulic lines to the operator.
[0056] The lock ring 34 has an internal thread to engage a corresponding thread on the housing 40 and the lock ring 34 also has an external thread (opposite to the said internal thread) to engage with an internal thread of the sleeve 35 . For this embodiment, the internal thread of the lock ring 34 is a right hand thread whilst the external thread of the lock ring 34 is a left hand thread, although it will be appreciated that in alternative embodiments the internal thread could be a left hand thread and the external thread could be a right hand thread. The benefit of using opposite threads is described below.
[0057] The external thread of the end cap 13 engaging with the inner thread of the sleeve 35 allows the sleeve 35 to also engage with the end cap 13 during transportation of the wireline BOP 1 . This protects the rods 33 which would otherwise be exposed when in their open position, shown in FIG. 6. To facilitate this, the sleeve 35 is threadably engaged on the lock ring 34 so they can move with respect to each other. In use however, the sleeve 35 does not engage the end cap 13 .
[0058] Apertures 36 are provided in the sleeve 35 , to allow a handle (not shown) to be inserted through the apertures 36 in order to manually turn the sleeve 35 .
[0059] In use, production fluids are recovered from the well (not shown) through flow lines (not shown) in a controlled manner.
[0060] In the event that the throughbore 3 requires to be closed, the ram 59 is hydraulically activated to close throughbore 3 (along with the opposite ram 58 shown in FIGS. 1 and 5), in a manner which will now be described. The hydraulic line coupled to the first coupling 65 is activated to inject pressurised hydraulic fluid through the first access port 66 , and in so doing, acts upon the outer most face of the main piston flange 50 such that the piston 6 is forced inwardly (right to left as shown in FIG. 3) until it has reached its full stroke and is in the closed configuration.
[0061] The back up system is then operated in order to hold the rams 58 , 59 in their closed position. The handle is inserted through apertures 36 of the sleeve 35 and the sleeve 35 is rotated with respect to the lock ring 34 , away from the throughbore 3 of the wireline BOP 1 until the lock ring 34 and sleeve 35 lock with respect to each other due to a suitable block (not shown) provided on their mutually engaging threads.
[0062] Continued rotation of the sleeve 35 causes the lock ring 34 and sleeve 35 to rotate as one, back towards the throughbore of the wireline BOP 1 since the threads between the housing 40 and lock ring 34 are opposite to those between the lock ring 34 and sleeve 35 . The lock ring 34 and sleeve 35 move toward the throughbore 3 until the front face of the lock ring 34 abuts with the rear or outer most ends of the rods 33 . The piston 6 and ram are thereby secured in the closed position via the rods 33 by the lock ring 34 . Therefore the lock ring 34 and sleeve 35 need to be able to move as one in order to move the lock ring 34 to back up the rods 33 and also to move with respect to each other in order to engage the sleeve 35 with the end cap 13 during transportation; the opposite threads on the lock ring 34 provide for this.
[0063] The rams 59 - 61 in the arms 9 - 11 are activated simultaneously in the same manner.
[0064] The channel 54 which balances the pressure between the throughbore 3 and the well bore pressure chamber 42 of the housing 40 reduces the strain on the rods 33 which would otherwise need to be far larger in diameter in order to cope with the pressure in the throughbore 3 acting on the ram 59 and piston 6 . Furthermore, the hydraulic fluid force used to move the ram 59 between the open and closed configurations can be at a considerably lower force than conventional wireline BOPs, since the force only needs to be high enough to overcome the friction between the various seals and the wireline BOP body 2 . As the skilled person will appreciate, this means that the size of the actuator assembly can be considerably reduced.
[0065] For certain embodiments of the invention, the lock ring 34 can be used to move the rams to close the throughbore 3 in the event of a hydraulic failure. This was impractical for previous wireline BOPs due to the pressure differential between the first and second ends of the actuator assembly which would resist movement of the lock ring 34 .
[0066] In order to open the rams 59 , the back-up system is removed by rotating the sleeve 35 in the opposite direction to that previously described, and the first hydraulic line connected to the first coupling 65 is de-activated such that the pressurised fluid is permitted to escape through the first hydraulic line. The hydraulic line coupled to the second coupling 67 is then activated to inject pressurised hydraulic fluid through the second access port 68 , and in so doing, acts upon the inner most face of the main piston flange 50 such that the piston 6 is forced outwardly (left to right as shown in FIG. 3) until it has returned its full stroke to the open configuration.
[0067] Certain embodiments of the invention generally benefit from smaller components in particular smaller pistons and rods which reduce the material required and costs to produce the wireline BOP 1 .
[0068] In certain preferred embodiments, the cross-sectional area of the piston 6 and ‘O’ ring seals 29 , 47 and 44 , 45 are varied independently; i.e. the pair of ‘O’ ring seals 29 and 47 and the associated diameter of the piston 6 (to the left hand side of the first piston flange 50 in FIG. 3) may be of a greater or lesser diameter than the ‘O’ ring seals 44 and 45 and the associated diameter of the piston 6 (to the right hand side of the first piston flange 50 in FIG. 3) in order to create an unbalanced force in either the opening or closing direction of the actuator assemblies, as desired. In such embodiments, the pressure in the bore 3 and the bore pressure chamber 42 are still equalised, but the increased surface area of the piston 6 at the bore 3 or the bore pressure chamber 42 results in the unbalanced force.
[0069] In a further alternative embodiment, a pump (not shown) may be provided instead of the channel 54 in the piston 6 in order to vary the pressure in the bore 42 of the housing 40 so that it is close to or the same as the pressure in the throughbore 3 .
[0070] In certain embodiments of the invention, the rods 33 perform two functions. The first, to provide a mechanical back-up to the piston 6 , and the second to indicate to an operator the extent of the stroke of the piston 6 .
[0071] Modifications and improvements may be made without departing from the scope of the invention. Those skilled in the art will realise that, although the embodiment hereinbefore described is employed in a wireline BOP valve, it could also be modified for use in other valves such as a drilling BOP or a coiled tubing BOP.
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A wireline valve/blowout preventor is capable of resisting the flow of fluids through a bore. At least one actuator assembly has a first and second end moveable between a first configuration in which fluids can flow through the bore, and a second configuration in which fluids flow through the bore is prevented. The first and second ends are each exposed to the pressure in the bore. A biasing arrangement may bias the actuator assembly toward one of the first and second configurations. A locking member may also be provided to abut with the actuator assembly when it is in the second configuration in order to prevent movement of the actuator assembly from the second configuration to the first configuration. Also, the actuator assembly may have at least one rod assembly which extends from the actuator assembly to a position where it is visible from an outside of the apparatus.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the earlier filed U.S. Provisional Patent Application No. 61/108,670 filed on Oct. 27, 2008, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The field of the invention is for cemeteries. More specifically, the field of invention is for a cemetery having a themed and unique configuration relating to an event, apparatus and the like.
BACKGROUND
[0003] Cemeteries and different burial places have been contemplated from the beginning of time. The human race has always desired the best ways to respect and bury their dead. The type of burial has changed over the centuries to include burning, burying, sending out to sea, building elaborate burial structures and the like.
[0004] The two most common types of burial methods today are cremation and casket burial. In more recent times, cremation has become more prevalent and is a little less expensive as it does not require acquiring a plot, or tombstone/gravestone. However, what is actually done with the cremation remains is often up to the families or the deceased. Many wish their ashes to be spread or placed at certain locations and others are stored by loved ones. The second traditional method of burial includes the use of a casket, plot and gravestone/mausoleum. The dead are prepared for burial, placed in a casket, and lowered into the ground. A gravestone or mausoleum is placed on top of the burial site to mark where the deceased is located. Typically, prior art cemeteries are parks with trees, grass and other park-like structures. Some prior art cemeteries are located on church grounds or other holy sites. Cremation remains are also sometimes found at these similar locations.
[0005] However, no significant developments have been made in the cemetery industry for some time. One way of denoting the interests and hobbies of the deceased individual is to carve the information directly onto the deceased headstone or gravestone. The information provided may give some idea of the individual's personal life, hobbies or other information that may immediately denote some characteristic or personal trait of the individual. Outside the markings of a headstone or gravestone, it is often very difficult to identify characteristics about the individual that may have identified their personal traits, interests or hobbies.
[0006] Therefore, a need exists for a new and unique cemetery theme that may allow the deceased some options when considering where and how to be buried. Additionally, a need exists for an improved cemetery which may provide greater deference and options to individuals that may be dictated by personal interests and hobbies while still giving the options for the type of burial ceremony, including cremation and/or traditional casket burial. Moreover, a need exists for an improved themed cemetery that may celebrate the common passion in the memorialization process, yet still give diverse burial options.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved cemetery experience whereby the cemetery and accompanying facilities may celebrate and demonstrate the passion and hobbies of the deceased individual. The contemplated themed cemetery may be a stand-alone cemetery that celebrates a common passion of a plurality of individuals, yet still maintains the traditional burial and memorialization process. The themed cemetery may take a specific event, or commonly understood and loved location and memorialize that location in the theme of a cemetery where those with that common interest and enjoyment of the commonly understood location may desire to be buried. The cemetery would closely resemble both visually and physically, a replica of the theme being celebrated and may provide space for the deceased while still providing adequate income and revenue in the way of advertising for the operator.
[0008] Among the many different possibilities contemplated, a themed cemetery may be provided for burial of the deceased.
[0009] To this end, in an exemplary embodiment of the present invention, a themed cemetery, the cemetery comprising: a portion of property replicating at least a venue both physically and visually; a plurality of plots located within the famous venue; said plots capable of holding traditional caskets and cremated remains; and at least a portion of the famous structure having advertising space thereon.
[0010] In an exemplary embodiment, the themed cemetery venue is a baseball stadium.
[0011] In an exemplary embodiment, the themed cemetery venue is a golf course.
[0012] In an exemplary embodiment, the themed cemetery venue is a football stadium.
[0013] In an exemplary embodiment, the themed cemetery venue is an automobile racetrack.
[0014] In an exemplary embodiment, the themed cemetery venue is a casino, building, racetrack, and/or any other notable structure.
[0015] In an exemplary embodiment, the themed cemetery plots are capable of holding human remains whereby the plots may have different revenue value depending on location within the famous venue.
[0016] In an exemplary embodiment, the themed cemetery advertising space is provided on the outside walls of the famous venue.
[0017] In an exemplary embodiment, the themed cemetery advertising and promotional space is provided within the venue to coincide with the advertising and promotional space provided at the corresponding real world facility for which the cemetery is modeled after.
[0018] In an exemplary embodiment, the themed cemetery advertising space is provided in the same locations where advertising is found in a real life famous venue.
[0019] In an exemplary embodiment, the themed cemetery further comprises: unique burial headstones having personal preferences that relate to the famous venue.
[0020] In yet another exemplary embodiment, a method for creating a themed cemetery is provided. The method comprising the steps of: providing a property which replicates at least a landmark venue both physically and visually; providing a plurality of plots located at different locations within the landmark venue; said plots located at different locations whereby said different locations being capable of holding either traditional caskets or cremated remains; and at least a portion of the famous structure having advertising space thereon.
[0021] In an exemplary embodiment, the method further comprises the step of: providing areas within the landmark venue capable of holding human remains whereby the plots have assigned values depending on the location within the landmark venue.
[0022] In an exemplary embodiment, the method further comprises the step of: allowing deceased individuals to be buried in a familiar location to social activities that the deceased member was involved in during their life, which is associated with the landmark venue.
[0023] In an exemplary embodiment, the method further comprises the step of: providing a seating area for visitors coming to the landmark venue whereby space is provided in the seating area for placement of deceased individuals' remains.
[0024] In an exemplary embodiment, the method further comprises the step of: said landmark venue being any of: a baseball stadium, a golf course, a basketball, hockey, football stadium, a car racing park, a traditional park, a casino, building, racetrack, famous landmark, structure or building.
[0025] In an exemplary embodiment, the method further comprises the step of: providing preferred locations within the landmark venue whereby the preferred locations provide increased revenue for burial at those locations.
[0026] In an exemplary embodiment, the method further comprises the step of: providing monuments, articles and memorabilia which are incorporated into the landmark venue to simulate and conjure up memories of the real world facility for which the themed cemetery is modeled thereafter.
[0027] In an exemplary embodiment, the method further comprises the step of: providing unique burial headstones and plots which have personal preferences and memorabilia that relate to the landmark venue.
[0028] In an exemplary embodiment, the method further comprises the step of: providing advertising and promotional space within the venue to coincide with the advertising and promotional space provided at the corresponding real world facility for which the cemetery is modeled after.
[0029] Additionally, in an exemplary embodiment, a themed cemetery may be provided whereby the cemetery may deliver a visual and a substantially similar replica of the theme being celebrated.
[0030] In yet another exemplary embodiment, it is contemplated that the themed cemetery may take the form of a scaled replica of a famous golf course.
[0031] In another exemplary embodiment, it is contemplated that the themed cemetery may take the form of a scaled replica of a football stadium such as Soldier Field, Lambeau Field, or Qualcomm Stadium.
[0032] A further exemplary embodiment contemplates that the themed cemetery may be formed to replicate a baseball stadium such as Wrigley Field, Fenway Park or Yankee Stadium.
[0033] In yet another exemplary embodiment, the themed cemetery may be adapted to replicate a driving forum such as the Daytona 500 and/or Talladega.
[0034] Additionally, in an exemplary embodiment, the themed cemetery may be adapted to replicate a famous casino, a famous building or any other structure, theme or hobby that may have been of interest to a plurality of deceased individuals.
[0035] In yet another exemplary embodiment of the present invention, the themed cemetery may celebrate a common passion and/or theme in every aspect of the traditional burial and memorialization process.
[0036] Still another exemplary embodiment of the present invention is to provide a themed cemetery whereby the theme is celebrated through the unique property design.
[0037] Yet another exemplary embodiment of the present invention is to provide a themed cemetery whereby the cemetery is specifically customized as a funeral and/or burial service with diverse burial options.
[0038] Still another exemplary embodiment is to provide a themed cemetery whereby the operators and creators of the cemetery would make every effort to deliver a visual and physical replica of the original venue to be celebrated, whether it may be a stadium, building or golf course.
[0039] Another exemplary embodiment of the invention is to provide a themed cemetery whereby the theme may be a NASCAR race track.
[0040] In yet another exemplary embodiment, a themed cemetery may be provided whereby the themed cemetery may utilize and capture the excitement of being at the actual themed event which the cemetery is designed after.
[0041] A further exemplary embodiment is to provide a themed cemetery whereby the physical size of the cemetery would be substantial in an effort to capture the feel of the true stadium, building, or venue.
[0042] Another exemplary embodiment is to provide a themed cemetery whereby the cemetery may have various portions thereof which may be of higher value to certain individuals, including bleachers which an individual may have spent a lot of time in, or premium boxes which may have been a favorite for the deceased. Similarly, an individual may wish to be buried in an infield portion of a stadium, or the pit area of a NASCAR themed cemetery, which may be chosen by the individual depending on their tastes.
[0043] A further exemplary embodiment is to provide a themed cemetery whereby the themed concept may be followed through in a design to include things like stadium seating that may be designed as community niches, which from a quantity standpoint may be most prevalent.
[0044] Still another exemplary embodiment is to provide a themed cemetery whereby the themed concept may be followed through in a design to include aspects such as viewing towers and private box niches, pit areas, winner's circles for car and horse racing venues, in-fields and end zones in stadium venues, and even outside walls that may be utilized to store the cremated remains of an individual.
[0045] Yet another exemplary embodiment is to provide a themed cemetery whereby the themed cemetery may also include a revenue stream for the operators by allowing advertising which have become common in most venues. The operator may sell advertising space on the outside walls, the pit areas, or box areas as are commonly found in most sporting venues. Thereby the operator of the cemetery may generate multiple revenue streams and may change the advertising space in the same manner as most venues change advertising space and use depending on time and other factors.
[0046] In another exemplary embodiment, the themed cemetery may be provide whereby the themed cemetery may be constructed to constitute any of a plurality of sporting or leisure events including baseball, basketball courts, hockey rinks, horse racing grounds, children's playgrounds, favorite restaurants, specific city buildings, country buildings, miniaturized landmarks, and the like.
[0047] In still another exemplary embodiment, unique tombstones, headstones and gravestones may be utilized to demonstrate a particular individual's interest in that venue. For example, an individual may have a personal connection to a certain individual car, green (for golf) or player, whereby the individual may utilize unique headstones that display their preferences within the themed cemetery.
[0048] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 illustrates a perspective diagram of the invention in an exemplary embodiment of the present invention;
[0050] FIG. 2 illustrates the entrance area and grandstand area of the invention in an exemplary embodiment of the present invention;
[0051] FIG. 3 illustrates a winning circle area of the present invention in an exemplary embodiment; and
[0052] FIG. 4 illustrates the inner green area of the present invention in an exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0053] The following description of a preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For ease of description, only one exemplary embodiment is herein described in detail. However, it should be understood that a person of ordinary skill in the art would contemplate that any of a plurality of embodiments may utilize the same themed cemetery construction for many different themes including stadiums, landmarks, buildings, parks, and the like. It should be understood that the use of a car racing stadium is utilized only for illustration purposes only and is in no way limited to only race car stadiums.
[0054] FIG. 1 illustrates an overall perspective view of a themed cemetery 1 . The themed cemetery 1 may take any of a plurality of shapes and sizes, depending on the desires and accommodations necessary for those wishing to be interned at the location. The themed cemetery 1 may take the form of a car racing facility 3 as illustrated in FIG. 1 , but may also take the form of any preferred landmarks, including sports stadiums, arenas, famous landmarks such as parks, buildings, structures, vehicles, trains, planes and the like. For illustrative purposes, FIG. 1 illustrates a themed cemetery 1 in the form of a racing car facility 3 such as those found in famous car racing tracks like Daytona raceway, (not shown) California raceway (not shown) and/or the Indianapolis raceway (not shown).
[0055] As illustrated in FIG. 1 , the themed cemetery 1 in the form of a racing car facility 3 may have a plurality of sections included therein. For example, the racing car facility 3 may have many of the same features commonly found on the actual racing car facility 3 for which it is modeled. The themed cemetery 1 may include grandstands 5 , commonly found in most real world racing car facilities. The grandstands 5 may include a plurality of areas including at least a seating area 7 , media box areas 9 , and grandstand burial areas 11 . It is contemplated that the grandstand 5 take the same form and shape as the real world racing car facilities and be approximately the same relational size to the real facilities. As mentioned earlier, the grandstands 5 of the themed cemetery 1 may have a seating area 7 which may be used by those individuals that come to visit those interned there. The seating area 7 of the grandstands 5 may also provide an area which may be suitably familiar to the individuals that may be visiting loved ones buried in the themed cemetery 1 . For example, friends that may have attended baseball games together and held season passes or attended race car events together and sat in the same location for years, may desire to sit in those same locations in the grandstands 5 when visiting the friends and/or relatives that may be buried at the themed cemetery 1 . A greater sense of familiarity may be provided with the seating area 7 of the grandstand 5 . Moreover, providing adequate seating area 7 may also allow for the accommodation of more people in the themed cemetery 1 and may also relax some of the anxiety related to visiting individuals at a cemetery.
[0056] Additionally, as illustrated in FIG. 1 , the themed cemetery 1 may also have a grandstand area 5 which may include media boxes 9 or luxury boxes. These media/luxury boxes 9 may be located in similar locations as those in the real world facilities. Many individuals have luxury boxes and a great deal of their social life while they were alive revolved around these luxury boxes 9 . These media/luxury boxes 9 may be utilized as either visitor areas or, in the alternative, may be utilized as burial areas for those wishing to be buried in the areas that many spent so much time in. However, as these media/luxury boxes 9 in real life cost significantly more than regular seating areas 7 , similarly, the media/luxury boxes 9 may cost more to be buried therein which may increase the exclusivity and profitability to the owner of the themed cemetery 1 facility. The luxury boxes 9 may encompass the entirety of the outside edge 13 of the themed cemetery 1 and may have the added advantage of looking out away from the themed cemetery 1 to property located adjacent (not shown). These luxury boxes 9 may include similar characteristics as those found in the real world facilities including glass 15 which looks towards the infield area 17 , the grandstand seating area 7 and even into the winning circle 25 , and the track 29 itself.
[0057] Included in the grandstands 5 may be a grandstand burial area 11 . As enumerated above, many individuals may have spent much of their time at a particular sporting event, such as season tickets for baseball games where the season ticket holder held the same seats for many years. The themed cemetery 1 may provide the individual with the ability to be buried or interned in much the same location or seating area where that individual may have spent so much of their leisure time. Additionally, visitors that knew the individual well, would know that the individual had been buried in the grandstand burial area 11 at a location that was close or at the location where that individual spent much of their leisure time. Many visitors may have at one point or the other, gone to a sporting event with the person interned or buried there and may have fond memories of their time with that individual. The grandstand burial area 11 may also provide nostalgic and/or fond memories for the individuals that visit the deceased, creating a positive atmosphere as opposed to the deserted, and desolate prior art cemetery grounds that provide the atmosphere that would provoke the fond and happy memories, thereby creating a positive cemetery visitor experience.
[0058] FIG. 1 also illustrates the track area 29 of the themed cemetery 1 car racing facility 3 . The track area 29 could be akin to the baseball field, football field, etc. of another type of facility and is utilized for illustrative purposes only. The track area 29 may have been the focus of the deceased individuals' attention when they were participating or viewing the event. The individual may have some fondness for being buried in the place for which they focused so much of their attention. From the facility owner's standpoint, the track area 29 or the field area in the case of a baseball field, or football field may comprise the majority of the area of the facility and may be the least expensive portion of the themed cemetery 1 to buy. Moreover, because the track area 29 may comprise a large portion of the surface area of the themed cemetery 1 , the facility owners may utilize the space to promote aesthetic features of the cemetery 1 including different vegetation/plants 31 , along with statues 35 , benches 37 (see FIG. 2 ) and the like. The track area 29 may allow for a park-like atmosphere which includes plants 31 , traditional seating areas 37 and walkways 39 which may allow visitors to walk around the track area 29 to view other parts of the themed cemetery 1 , sit in the grandstands 5 and to find the appropriate loved family or friend that may be interned or buried at a particular location within the track area 29 .
[0059] The track area 29 may even be divided into a first area 41 and a second area 43 . The first area 41 may comprise more uniform tombstones 47 that lie at ground level and may complete the aesthetic appearance of a track area 29 . Moreover because of their proximity to other tombstones 49 , the first area 41 may be marketed as a cheaper area to purchase than other areas of the themed cemetery 1 . The second area 43 of the track area 29 may be marketed by the facility owners as a more expensive, larger plot area of the themed cemetery 1 . As illustrated in FIG. 2 , more ornate tombstones 51 may be located in this second area 43 than those present in the first area 41 of the track area 29 . The tombstones 51 may include larger headstones 55 , mausoleums 57 and/or more decorative and specific memorials 59 . These specific memorials 59 may include figures such as racing cars 61 , favorite players/drivers, favorite number designators 63 and many other optional indicia that may show the deceased's preferred and/or love for that specific pastime. FIG. 2 further illustrates the themed cemetery 1 and the continuation of the theme throughout the entire facility, which in the case of the race car facility 3 , may include the general presence of racing flags, such as winner's flags, caution flags, and the like that may be incorporated both figuratively into the ground coverings, and other memorial areas and may even include things like trophies 69 which may be placed ornamentally around the entirety of the race car facility 3 themed cemetery 1 . Additionally, it is contemplated that the second area 43 may have specific memorials 59 and larger headstones 55 , which would likely necessitate larger spaces between a first plot 71 and a second plot 73 . Thereby walkways 39 may be incorporated between a first plot 71 and a second plot 73 and vegetation 31 may be incorporated into the spaces therebetween.
[0060] FIG. 2 further illustrates the winner's circle area 25 of the themed cemetery 1 . The winner's circle area 25 may be set up similarly to the winner's circle of the real world facility. Moreover, the winner's circle area 25 may be marked with ornate decorations such as vegetation 31 and trophies 69 which may mark it as such. Additionally, it is contemplated that the winner's circle may be utilized as a burial place for those wishing to be buried in this specific area whereby the facility owner may choose to charge a premium for burial at that specific location or may use the winner's circle as a visitor's area only with seating areas and the like set up. The winner's circle 25 may be at a focal point to the entire themed cemetery 1 , whereby the grandstands 5 and the track area 29 all encircle the winner's circle 25 which may increase the value and location of the burial spots close to the winner's circle 25 . Individuals may wish to be buried near that area as many people will desire to visit this area because of its unique ornamentation including plaques and potentially other memorabilia from actual races/sporting events.
[0061] Also illustrated in FIG. 2 is the outside edge 79 of the second area 42 of the track area 29 . As can be seen, larger headstones 55 may be located in this area that may be adjacent to the winner's circle 25 . Moreover, statues 81 may also be placed in this area. In an exemplary embodiment, a statute 81 representing the likeness of a deceased individual may be displaced whereby the individual statue 81 may be wearing their favorite jacket/article 83 of clothing having the indicia of the sporting event or the racing number 85 of their favorite driver thereon. The statue may be displayed to show the deceased individual's love and enthusiasm for a particular sport, event or particular individual, driver or the like, yet still have the personalized touch of bearing the likeness of the deceased individual. Again, the use of the deceased individuals' pastimes may bring joy and fond memories to those visitors that are visiting the themed cemetery 1 . The atmosphere may also play a part in encouraging the fond memories of visitors that come into the themed cemetery 1 such that they may re-live some of the experiences that they may have had with their departed loved ones.
[0062] FIG. 3 further illustrates the grandstands area 5 and the entrance area 87 of the themed cemetery 1 . As can be appreciated, the entrance area 87 may lead directly onto the track area 29 and into the grandstand area 5 as would be normally found in a real world facility. Facility owners may also lease the space in the entrance area, or the outside surface of the themed cemetery 1 to potential sponsors and/or advertisers that may wish to advertise and sponsor the facility. This may allow for increased revenue in the themed cemetery 1 and may also lead to the credibility of the facility as many of the real world facilities have similar sponsorships and advertising appearances throughout the entire facility. For example, if a stadium has advertisements placed along the outfield wall, the themed cemetery 1 may lease the space to potential sponsors or businesses that wish to lease the space which would make the themed cemetery 1 look similar to the real world stadium advertisements that people have come accustomed to seeing in the real world facility.
[0063] FIG. 3 also illustrates the grandstand area 5 with stairs 89 leading to the grandstands area 5 and stairs 89 leading to the track area 29 . The grandstands area 5 may have a plurality of walls 91 which may separate the grandstand areas 5 from the track area 29 . The walls 91 may also be set up to accept urns holding the cremated remains of the deceased. Each section of the wall 91 may have plaques 93 located thereon which may identify the final resting place of the individuals interned within that area. It should be understood that the walls 91 may be of sufficient thickness to allow for a plurality of cremated remains to be placed within them, along with the plaques 93 which identify the individual's identity. Also included in the grandstand area 5 as illustrated in FIG. 1 may be a seating area for visitors to come and spend time at the themed cemetery 1 when visiting loved ones.
[0064] FIG. 4 illustrates the inner field area 101 of the themed cemetery 1 . The inner field area 101 may continue the theme of the facility. In this exemplary embodiment, the inner field area 101 of a race car facility may comprise mechanic pits and other holding areas. In this particular embodiment, it may be more desirable to have an inner field area 101 which may be more park like with ponds 103 , seating areas 105 and other ornamental features 107 which are still consistent with the overall themed cemetery 1 which may include pedestals 111 having cars, trophies and other activities associated with the theme. Additionally, walkways 113 may be provided to allow walking from one side 115 of the track area 29 to a second side 117 of the track area 29 . Other ornamental features and characteristics may be provided to enhance the theme of the cemetery while not detracting from the aesthetic pleasure of the surrounding areas.
[0065] The above-described device may be altered by means known in the art without departing from the spirit and scope of this invention.
[0066] The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. The terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.
[0067] While the invention has been described in what is presently considered to be an exemplary embodiment, many variations and modifications will become apparent to those skilled in the art. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiment, but be interpreted within the full spirit and scope of the appended claims.
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An improved cemetery experience whereby the cemetery and accompanying facilities may celebrate and demonstrate the passion and hobbies of the deceased individual. The contemplated themed cemetery may be a stand-alone cemetery that celebrates a common passion of a plurality of individuals, yet still maintains the traditional burial and memorialization process. The themed cemetery may take a specific event, or commonly understood and loved location and memorialize that location in the theme of a cemetery where those with that common interest and enjoyment of the commonly understood location may desire to be buried. The cemetery would closely resemble both visually, and physically a replica of the theme being celebrated and may provide space for the deceased while still providing adequate income and revenue in the way of advertising for the operator.
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BACKGROUND
1. Technical Field
The present invention relates to cloud based virtual networks, and more particularly, to a virtual machine replication scheme applicable to such networks.
2. Discussion of the Related Art
As enterprise workloads are migrated to the cloud, it is essential that hybrid and/or multi-cloud deployments are supported. However, enterprise workloads often contain servers or network components that act as choke points that may be tied to a single site and difficult to replicate. For example, many servers may communicate with a stateful firewall, dynamic host configuration protocol (DHCP) server, authentication server or file server. Servers on different clouds cannot communicate with these components locally, thereby causing significant traffic overhead between clouds or requiring the redesign of the application or component. FIGS. 1-3 exemplarily illustrate this scenario.
For example, FIG. 1 shows an enterprise workload built from a virtual network that includes virtual machines VM 1 -VM 4 and a middlebox MB in a cloud computing environment 110 . The middlebox MB may be a virtual machine that performs packet inspection, protocol acceleration, DHCP, authentication, etc. of traffic flowing between VM 1 -VM 4 , for example. The dashed lines between the virtual machines VM 1 and VM 2 and the middlebox MB illustrate traffic flowing from VM 1 to VM 2 and vice versa. The dashed lines between the virtual machines VM 3 and VM 4 and the middlebox MB illustrate traffic flowing from VM 3 to VM 4 and vice versa. FIG. 2 shows that even when the virtual machines VM 3 and VM 4 are moved to cloud computing environment 120 , their traffic must still go through the middlebox MB in the cloud computing environment 110 . FIG. 3 shows that the movement of the middlebox MB to the cloud computing environment 120 does not help much as traffic flow between VM 1 and VM 2 in the cloud computing environment 110 must still pass through the middlebox MB.
As can be seen, the placement of the middlebox MB in the cloud computing environment 110 or 120 can lead to a drop in performance of the virtual network. For example, in the case shown in FIG. 3 , the traffic must leave the cloud computing environment 110 to be processed by the middlebox MB in the cloud computing environment 120 . This transit takes time and affects latency. This transit also increases cost, since traffic leaving a cloud costs additional monies.
BRIEF SUMMARY
The present invention discloses a virtual machine replication scheme that improves performance of cloud based virtual networks.
In an exemplary embodiment of the present invention, the method includes: replicating a first virtual machine (VM) found in a first cloud computing environment and putting the replicated VM in a second cloud computing environment; activating the first VM and pausing the replicated VM; first processing, at the first VM, traffic from VMs in the first cloud computing environment, wherein the first processing occurs when the first VM is activated and the replicated VM is paused; first buffering, at a hypervisor corresponding to the replicated VM, traffic from VMs in the second cloud computing environment, wherein the first buffering occurs when the first VM is activated and the replicated VM is paused; activating the replicated VM in response to state information of the first VM and pausing the first VM; and second processing, at the replicated VM, the first buffered traffic according to the state information of the first VM, wherein the second processing occurs when the replicated VM is activated and the first VM is paused.
In an exemplary embodiment of the present invention, the method includes replicating a first VM to produce a second VM; activating the first VM and pausing the second VM; first processing traffic at the first VM, wherein the first processing occurs when the first VM is activated and the second VM is paused; buffering, at a virtual machine manager of the second VM, traffic destined for the second VM, wherein the first buffering occurs when the first VM is activated and the second VM is paused; activating the second VM in response to state information of the first VM and pausing the first VM; and second processing, at the second VM, the buffered traffic according to the state information of the first VM, wherein the second processing occurs when the second VM is activated and the first VM is paused.
In an exemplary embodiment of the present invention, the method includes replicating a first VM to produce a second VM and a third VM; activating the first VM and pausing the second VM and the third VM; first processing traffic at the first VM, wherein the first processing occurs when the first VM is activated and the second and third VMs are paused; first buffering, at a virtual machine manager of the second VM, traffic destined for the second VM, wherein the first buffering occurs when the first VM is activated and the second and third VMs are paused; second buffering, at a virtual machine manager of the third VM, traffic destined for the third VM, wherein the second buffering occurs when the first VM is activated and the second and third VMs are paused; activating the second VM in response to state information of the first VM and pausing the first VM; and second processing, at the second VM, the first buffered traffic according to the state information of the first VM, wherein the second processing occurs when the second VM is activated and the first and third VMs are paused.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 illustrates a prior art virtual network configuration in a single cloud;
FIG. 2 illustrates a prior art virtual network configuration across clouds;
FIG. 3 illustrates a prior art virtual network configuration across clouds;
FIG. 4 illustrates a virtual network configuration across clouds, according to an exemplary embodiment of the present invention;
FIGS. 5 and 6 illustrate the operation and configuration of a virtual machine (VM), its virtual machine manager (VMM), a replica of the VM and the replica's VMM, according to an exemplary embodiment of the present invention; and
FIG. 7 illustrates an apparatus for implementing an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
A cloud or a cloud computing environment may refer to the delivery of computing as a service rather than a product, whereby shared resources, software, and information are provided to computers and other devices as a metered service over a network (typically the internet).
A virtual machine (VM) may be a software implementation of a machine (e.g., a computer) that executes programs like a physical machine. VMs may be separated into two major categories, based on their use and degree of correspondence to any real machine. A system VM provides a complete system platform which supports the execution of a complete operating system (OS), for example. In contrast, a process VM is designed to run a single program, which means that it supports a single process, for example. An essential characteristic of a VM is that the software running inside is limited to the resources and abstractions provided by the VM, thus it cannot break out of its virtual environment.
As stateful VM may mean the VM keeps track of the state of an interaction, usually by setting values in a storage field designated for that purpose.
An enterprise workload may consist of a number of VMs that communicate with each other to form a network topology. Each VM may contain an application component or a middlebox that may be shared by multiple applications. An example enterprise workload may consist of two “three-tier” applications (a three-tier application includes a web server, an application server and a database, for example) in which all traffic from either Web tier must flow through a shared middlebox VM acting as a firewall or an intrusion detection system.
In brief, the present invention discloses a method and apparatus to replicate stateful VMs between multiple clouds, even if the VMs were not designed to be easily replicated. Replica VMs may be identical, down to the memory contents, internet protocol (IP) address and network connections that they contain. However, unlike standard replication schemes, according to the present invention, traffic can enter either of the VM replicas: there is no concept of master and slave. Additionally, only one of the VM replicas may be running at any one time. In other words, the replicas are time multiplexed. For example, before a replica begins to run, the two replicas become synchronized via a snapshot update of the VM memory state from the other replica, thus ensuring that the internal state of the VM (or replica) is always consistent.
Traffic at each site (e.g., cloud) is destined for its local replica. If the replica is currently running, the traffic proceeds into the VM for processing. Otherwise, the traffic is buffered until the replica becomes active.
This present inventive approach requires no knowledge of the internal workings of the VM; it operates at the hypervisor level. Furthermore, the potential diversion of every network packet to a different cloud is avoided: resulting in reduced cost both monetarily (clouds charge a fee for data coming in and going out of the cloud) and in terms of latency.
FIG. 4 illustrates a virtual network configuration across clouds, according to an exemplary embodiment of the present invention. In FIG. 4 , middlebox MBy is a replica of middlebox MBx. A VM may be replicated by temporarily suspending the VM and copying all virtual memory, virtual central processing unit (CPU), and virtual device state to another physical machine, after which either the VM or its replica can be resumed. As shown in FIG. 4 , traffic within the cloud computing environment 110 proceeds through the middlebox MBx and traffic within the cloud computing environment 120 proceeds through the middlebox MBy.
In an exemplary embodiment of the present invention, when the middlebox MBx is active, traffic from VM 1 and VM 2 in the cloud computing environment 110 is processed. While the middlebox MBx is active, the middlebox MBy is paused. While the middlebox MBy is paused, traffic from VM 3 and VM 4 in the cloud computing environment 120 is buffered at the hypervisor (or virtual machine manager (VMM)) of the middlebox MBy. These processes will now be described in detail with reference to FIGS. 5 and 6 , with reference back to FIG. 4 .
In FIG. 5 , there is shown the middlebox MBx in the active state and the middlebox MBy in the paused state. The middlebox MBx has its own hypervisor VMMx and the middlebox MBy has its own hypervisor VMMy. The hypervisor VMMx includes a buffer and a flip engine. The hypervisor VMMy includes a buffer and a flip engine. Since the middleboxes MBx and MBy are replicas, the buffers are the same as each other and the flip engines are the same as each other. In other words, architecturally, the buffers and the flip engines are the same. However, each buffer will be holding different network packets destined for MBx or MBy, respectively.
The buffer may be a reserved portion of memory on a physical machine which temporarily stores incoming network traffic while a replica is inactive. The flip engine may be a small program that determines when an active replica should become inactive and selects a target replica that should become active, based on the state of the buffer and/or input from other programs or users. A user may do this via an interface. The flip engine may also be responsible for transferring the state that was updated since the local active replica started to run the target replica.
When the middlebox MBx is active, as shown in FIG. 5 , the middlebox MBx processes incoming traffic. For example, the middlebox MBx may process traffic from VM 1 and VM 2 in the cloud computing environment 110 of FIG. 4 . However, the middlebox MBx may process traffic from VMs in another cloud. The actions performed by the middlebox MBx depend on the type of middlebox. For example, a firewall middlebox may examine headers on received packets, compare them against firewall rules and drop the packets if they violate any rules. In general, a middlebox may examine traffic and/or modify it as packets are processed.
After being processed by the middlebox MBx, the outgoing traffic is provided to the VMs in the cloud computing environment 110 . However, the outgoing traffic may be provided to VMs in another cloud. While the middlebox MBx is active, the paused middlebox MBy may buffer incoming traffic. In this case, traffic from VM 3 and VM 4 in the cloud computing environment 120 may be kept in the buffer of hypervisor VMMy. The middlebox MBy also process traffic from VMs in another cloud.
While the middlebox MBx is active and processing incoming traffic, the modified state of the middlebox MBx is maintained in the flip engine of the middlebox MBx. Variables in the memory of the middlebox MBx may be updated; for example, a counter may be incremented or a firewall rule may be updated. In addition, the virtual CPU state, identifying which instruction the middlebox MBx is currently executing will continuously update. Depending on a particular circumstance, for example, when the number of packets received at the middlebox MBx reaches a predetermined threshold, when the number of packets stored in the buffer of the hypervisor VMMy reaches a predetermined threshold, or to achieve a target latency (e.g., by avoiding long packet wait times in the buffer), the flip engine sends a state delta signal (also shown as 130 in FIG. 4 ) to the paused middlebox MBy.
The state delta includes virtual memory and virtual CPU states that have been updated since the middlebox MBx became active. To track the modified virtual memory state, shadow memory techniques can be applied, as used for example in Cully et al., “Remus: High Availability via Asynchronous Virtual Machine Replication,” NSDI 2008, pp. 161-174, the disclosure of which is incorporated by reference herein in its entirety. The state delta also includes the virtual CPU state maintained by the VMMx corresponding to the middlebox MBx.
In response to the state delta, the middlebox MBy is activated as shown in FIG. 6 . The middlebox MBx is paused at this time. Because the middlebox MBy received the state delta, which includes the last state of the middlebox MBx, the now active middlebox MBy is able to process the traffic stored in its buffer at that state. Based on the state delta, the memory pages modified by the middlebox MBx overwrite the state memory pages in the middlebox MBy before the middlebox MBy becomes active. Similarly, the virtual CPU context that the middlebox MBx was running is copied to the middlebox MBy. In other words, the middlebox MBy operates in synch with the middlebox MBy.
After the middlebox MBy finishes processing the packets stored in its buffer, the middlebox MBy processes incoming traffic. Since the middlebox MBx is paused, traffic destined for the middlebox MBx is stored in the buffer of the hypervisor VMMx. Similar to that described above, once the determination is made to reactivate the middlebox MBx, the flip engine of the hypervisor VMMy will send the state delta to the flip engine of the middlebox MBx and the middlebox MBx will first process the data stored in its buffer, and then, any new incoming packets. The middlebox MBy will be paused and operate like a paused VM as described above.
Although not shown, the present invention may be applicable to more than two replicated VMs. In this case, a set of scheduling policies may be used to trigger flips. For example, using a load balancing technique, the flip engine of an active VM may send a state delta to an inactive VM based on a comparison of the amount of data in each of the buffers of the inactive VMs. Thus, the VM with the most packets gets to run next.
In addition, the present invention provides a methodology to collapse the replicas back into a single instance. If, for any reason, multiple replicas are no longer necessary (e.g., all VMs are migrated to the same cloud), a VM one of the replicas can be selected to be destroyed. When the dying replica finishes its last period of activity, its buffer is marked as inactive and all packets from the virtual network that would have been received by the replica's buffer are diverted to a still living replica. All flip engines are notified of the departure of a replica so that it will not be scheduled again. Then, the VMM can reclaim the resources associated with the replica. This process can be repeated for all replicas until a single VM remains.
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article or manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
Referring now to FIG. 7 , according to an exemplary embodiment of the present invention, a computer system 701 can comprise, inter alia, a CPU 702 , a memory 703 and an input/output (I/O) interface 704 . The computer system 701 is generally coupled through the I/O interface 704 to a display 705 and various input devices 706 such as a mouse and keyboard. The support circuits can include circuits such as cache, power supplies, clock circuits, and a communications bus. The memory 703 can include RAM, ROM, disk drive, tape drive, etc., or a combination thereof. Exemplary embodiments of present invention may be implemented as a routine 707 stored in memory 703 (e.g., a non-transitory computer-readable storage medium) and executed by the CPU 702 to process the signal from the signal source 708 . As such, the computer system 701 is a general-purpose computer system that becomes a specific purpose computer system when executing the routine 707 of the present invention.
The computer platform 701 also includes an operating system and micro-instruction code. The various processes and functions described herein may either be part of the micro-instruction code or part of the application program (or a combination thereof) which is executed via the operating system. In addition, various other peripheral devices may be connected to the computer platform such as an additional data storage device and a printing device.
The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical functions(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A method including replicating a first virtual machine (VM) in a first cloud and putting the replicated VM in a second cloud. Activating the first VM and pausing the replicated VM. First processing, at the first VM, traffic from VMs in the first cloud, wherein the first processing occurs when the first VM is activated and the replicated VM is paused. Buffering, at a hypervisor of the replicated VM, traffic from VMs in the second cloud, wherein the buffering occurs when the first VM is activated and the replicated VM is paused. Activating the replicated VM in response to state information of the first VM and pausing the first VM. Second processing, at the replicated VM, the buffered traffic according to the state information of the first VM, wherein the second processing occurs when the replicated VM is activated and the first VM is paused.
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TECHNICAL FIELD
[0001] The present invention relates to synchronization between mobile devices and fixed devices, and, more specifically, to systems for resolving conflicts detected during a synchronization session between the mobile device and the fixed device.
BACKGROUND OF THE INVENTION
[0002] Mobile devices, sometimes referred to as handheld devices, have become quite common today. The users of these mobile devices want to have their mobile device updated with current information quite frequently. The process for updating information involves communicating with a fixed device (i.e., server) and is commonly referred to as a synchronization session. Between synchronization sessions, the mobile device may change information in its mobile store and the fixed device may change information in its server store. If the information that is changed in the mobile store and the server store is associated with the same data object, a conflict is detected during the next synchronization session. In these situations, prior systems that synchronized data objects would provide some type of user interface on the mobile device that would indicate that the conflict existed and that the conflict was with a certain object. In one example, the device user would receive a notification regarding the conflict, when, in fact, the information changed on the object associated with the notification had identical information on both devices (i.e., both devices changed a last name field of a contact object from a maiden name to a married name). In addition to the unhelpful user interface that was provided, prior systems would also keep both versions of the data objects having the conflict on both the mobile device and on the fixed device. As one can imagine, keeping both objects wasted memory on the devices and caused extra work for the user to resolve the otherwise duplicate objects. In addition, sending the other version of the object used bandwidth on the data channel between the devices. Thus, there is a need for an improved method for resolving conflicts detected during a synchronization session that enhances the mobile user's experience.
SUMMARY OF THE INVENTION
[0003] Briefly described, the present invention provides a method for resolving a conflict detected while synchronizing a first data object in a first store associated with a mobile device and a second data object in a second store associated with a server. In accordance with the present invention, certain conflicts are automatically resolved without requiring user-intervention on the mobile device and without duplicating data objects on either the mobile device or the server.
[0004] In general, once a conflict is detected, properties of the first data object are compared with corresponding properties of the second data object. If the corresponding properties that differ are designated as mergeable properties, the corresponding properties are merged. Merging the properties involves sending a preferred state associated with each of the conflicting properties to the mobile device and the server for updating the first data object and second data object, respectively, when an initial state for the properties and the corresponding properties is different than the preferred state. The preferred state is based on a likelihood that vital information would be lost if the preferred state did not replace the initial state of the property or the corresponding property. For example, if a read property for an email object is marked as read on the mobile device and as unread on the server, the preferred state (unread) is sent to the mobile device to update the email object. Thus, a user is insured that if data is lost, the most conservative approach to data loss results, thereby reducing the danger of the data loss. The merging is performed without user-intervention on the mobile device. In addition, the entire first data object or second data object is not sent to the mobile device to achieve the merge, thereby minimizing the data transfer to the mobile device.
[0005] In another aspect of the invention, a system for resolving a conflict detected during a synchronization session is provided. The system includes a first device, a second device, and a server. The first device is associated with a first data store that stores several data objects. The second device is associated with a second data store that stores several corresponding data objects. Each data object in the first data stores is associated with one of the corresponding data objects in the second data store. The server is configured to detect a conflict between the data objects and their corresponding data objects by determining whether a property of the data object is different than a corresponding property of the corresponding data object. If the property and the corresponding property are designates as mergeable properties, the server is configured to merge the property of the data object and the corresponding property. The merging is performed without user-intervention on the first device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 illustrates an exemplary computing device that may be used in one exemplary embodiment of the present invention;
[0007] [0007]FIG. 2 illustrates an exemplary mobile computing device that may be used in one exemplary embodiment of the present invention;
[0008] [0008]FIG. 3 is a functional block diagram of one exemplary conflict resolution system as implemented using the computer device shown in FIG. 1 and the mobile computing device shown in FIG. 2;
[0009] [0009]FIG. 4 is a graphical representation of one embodiment of the salient portions of a sample data object;
[0010] [0010]FIG. 5 is a logical flow diagram generally illustrating an overview of a synchronization process with conflict resolution;
[0011] [0011]FIG. 6 is a logical flow diagram illustrating a conflict resolution process suitable for use in FIG. 5; and
[0012] [0012]FIG. 7 is a logical flow diagram illustrating a user-selectable conflict process suitable for use in FIG. 6, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] The present invention may be implemented in one or more components operating within a distributed or wireless computing network. Those components may include software programs or applications operating on computing systems of various configurations. Two general types of computing systems are being used to implement the embodiments of the invention described here. Those two general types are illustrated in FIG. 1 and FIG. 2 and described below, followed by a detailed discussion of one illustrative implementation of the invention, illustrated in FIGS. 3 - 7 , based on these two types of computer systems.
[0014] Illustrative Operating Environment
[0015] With reference to FIG. 1, one exemplary system for implementing the invention includes a computing device, such as computing device 100 . In a very basic configuration, computing device 100 typically includes at least one processing unit 102 and system memory 104 . Depending on the exact configuration and type of computing device, system memory 104 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. System memory 104 typically includes an operating system 105 , one or more program modules 106 , and may include program data 107 . This basic configuration is illustrated in FIG. 1 by those components within dashed line 108 .
[0016] Computing device 100 may have additional features or functionality. For example, computing device 100 may also include additional data storage devices (removable and/or non-removable) such as, for example, magnetic disks, optical disks, or tape. Such additional storage is illustrated in FIG. 1 by removable storage 109 and non-removable storage 110 . Computer storage media may include volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer readable instructions, data structures, program modules, or other data. System memory 104 , removable storage 109 and non-removable storage 110 are all examples of computer storage media. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computing device 100 . Any such computer storage media may be part of device 100 . Computing device 100 may also have input device(s) 112 such as keyboard, mouse, pen, voice input device, touch input device, etc. Output device(s) 114 such as a display, speakers, printer, etc. may also be included. These devices are well know in the art and need not be discussed at length here.
[0017] Computing device 100 may also contain communication connections 116 that allow the device to communicate with other computing devices 118 , such as over a network. Communications connections 116 is one example of communication media. Communication media may typically be embodied by computer readable instructions, data structures, program modules, or other data in a modulated data signal, such as a carrier wave or other transport mechanism, and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. The term computer readable media as used herein includes both storage media and communication media.
[0018] With reference to FIG. 2, one exemplary system for implementing the invention includes a mobile computing device, such as mobile computing device 200 . The mobile computing device 200 has a processor 260 , a memory 262 , a display 228 , and a keypad 232 . The memory 262 generally includes both volatile memory (e.g., RAM) and non-volatile memory (e.g., ROM, Flash Memory, or the like). The mobile computing device 200 includes an operating system 264 , such as the Windows CE operating system from Microsoft Corporation or other operating system, which is resident in the memory 262 and executes on the processor 260 . The keypad 232 may be a push button numeric dialing pad (such as on a typical telephone), a multi-key keyboard (such as a conventional keyboard). The display 228 may be a liquid crystal display, or any other type of display commonly used in mobile computing devices. The display 228 may be touch sensitive, and would then also act as an input device.
[0019] One or more application programs 266 are loaded into memory 262 and run on the operating system 264 . Examples of application programs include phone dialer programs, email programs, scheduling programs, PIM (personal information management) programs, word processing programs, spreadsheet programs, Internet browser programs, and so forth. The mobile computing device 200 also includes non-volatile storage 268 within the memory 262 . The non-volatile storage 268 may be used to store persistent information which should not be lost if the mobile computing device 200 is powered down. The applications 266 may use and store information in the storage 268 , such as e-mail or other messages used by an e-mail application, contact information used by a PIM, appointment information used by a scheduling program, documents used by a word processing application, and the like. A synchronization application also resides on the mobile computing device 200 and is programmed to interact with a corresponding synchronization application resident on a host computer to keep the information stored in the storage 268 synchronized with corresponding information stored at the host computer.
[0020] The mobile computing device 200 has a power supply 270 , which may be implemented as one or more batteries. The power supply 270 might further include an external power source, such as an AC adapter or a powered docking cradle, that supplements or recharges the batteries.
[0021] The mobile computing device 200 is also shown with two types of external notification mechanisms: an LED 240 and an audio interface 274 . These devices may be directly coupled to the power supply 270 so that when activated, they remain on for a duration dictated by the notification mechanism even though the processor 260 and other components might shut down to conserve battery power. The LED 240 may be programmed to remain on indefinitely until the user takes action to indicate the powered-on status of the device. The audio interface 274 is used to provide audible signals to and receive audible signals from the user. For example, the audio interface 274 may be coupled to a speaker for providing audible output and to a microphone for receiving audible input, such as to facilitate a telephone conversation.
[0022] The mobile computing device 200 also includes a radio interface layer 272 that performs the function of transmitting and receiving radio frequency communications. The radio interface layer 272 facilitates wireless connectivity between the mobile computing device 200 and the outside world, via a communications carrier or service provider. Transmissions to and from the radio interface layer 272 are conducted under control of the operating system 264 . In other words, communications received by the radio interface layer 272 may be disseminated to application programs 266 via the operating system 264 , and vice versa.
[0023] Illustrative Conflict Resolution System
[0024] [0024]FIG. 3 is a functional block diagram generally illustrating one embodiment for a synchronization system with conflict resolution 300 that resolves conflicts between data objects detected during a synchronization session between a fixed computing device, such as an information server 310 and a mobile device 320 , in accordance with the present invention. In this implementation, the information server 310 is a computing device such as the one described above in conjunction with FIG. 1, and the mobile device 320 (i.e., client) is a mobile computing device such as the one described above in conjunction with FIG. 2. A synchronization application 342 performs the synchronization process between the information server 310 and the mobile device 320 . The synchronization application 342 includes a conflict manager 380 for detecting and resolving the conflicts during the synchronization sessions. In the embodiment illustrated, the synchronization application 342 resides on a synchronization server 340 , which is a computing device as described above in conjunction with FIG. 1. Alternatively, the synchronization application 342 may reside in any acceptable location, such as directly on the information server 340 or on the mobile device 320 . The synchronization server 340 is shown coupled to the information server 310 over a local or wide area network in the conventional manner. In another embodiment, the synchronization application 342 may reside on information server 310 without departing from the scope of the present invention.
[0025] The mobile device 320 maintains mobile data 322 (i.e., a mobile data store) locally in its non-volatile storage 268 (shown in FIG. 2). Information server 310 maintains server data 312 (i.e., a server data store) on its removable storage 109 or non-removable storage 110 (shown in FIG. 1). As mentioned earlier, the mobile data 322 and the server data 312 may include e-mail or other messages used by an e-mail application, contact information used by a PIM, appointment information used by a scheduling program, and the like. Typically, each type of data in the mobile data 322 or server data 312 is referred to as a “collection” (e.g., e-mail and contacts are two separate collections). Each collection includes a plurality of data objects. For example, the server data 312 includes a plurality of server data objects 314 and the mobile data 322 includes a plurality of mobile data objects 324 . A representative illustration of the salient portions of a sample data object is illustrated in FIG. 4 and described below.
[0026] The mobile device 320 may change the mobile data 322 on the mobile device 320 at anytime. Once the mobile data 322 is changed, server data 312 accessible by the information server 310 will not have identical information. Similarly, the information server 310 may change the server data 312 , such as through any number of networked personal computers (not shown) connected to the information server 310 . Again, once the server data 312 is changed, the mobile data 322 and server data 312 are no longer identical (i.e., data is not synchronized and the changes on both sides create a conflict). In order for the mobile data 322 and the server data 312 to become identical (i.e., synchronized), typically, the mobile device 320 initiates a synchronization session. During the synchronization session, the synchronization application 342 attempts to update the server data objects 314 and the mobile data objects 324 to have identical information. In other words, after a successfully synchronization session, the server data objects 314 will have a corresponding mobile data object 324 with the same information.
[0027] Briefly, during the synchronization session of one embodiment of the present invention, client synchronization data 330 is transmitted between the mobile device 320 and the synchronization application 342 , and server synchronization data 350 is transmitted between the synchronization application 342 and the information server 310 . The client synchronization data 330 specifies changes to the mobile data 322 since the last successful synchronization session and specifies changes to the server data 312 that the mobile device 320 should update on its mobile data 322 . The server synchronization data 350 specifies changes that the information server 310 should make to its server data 312 and specifies changes to the server data 312 that the mobile device 320 should make to its mobile data 322 . The synchronization application 342 saves information regarding the synchronization session in a synchronization state table 344 .
[0028] During the synchronization sessions, the conflict manager 380 , briefly described here and illustrated in FIGS. 5 - 7 and described in detail below, determines which of the changes to the mobile data 322 and the server data 312 involve a conflict. After determining there is a conflict, the conflict manager 380 attempts to resolve the conflict without sending a conflict notification 382 to the mobile device 320 . In one embodiment, the client synchronization data 330 includes a parameter 332 , described in more detail with reference to FIGS. 6 and 7, that specifies how automatic conflict resolution should be handled. However, when certain types of conflicts occur, a conflict notification 382 is sent to the mobile device 320 . A sample XML message is shown below that represents a general format for one embodiment of the conflict notification 382 sent to the mobile device 320 .
<SYNC> . . . <COLLECTION> <COLLECTIONTYPE>E-MAIL</> <RESPONSES> <RESPONSE> <OBJECT ID>123</> <COMMAND>CHANGE</> <STATUS>READ FLAG MODIFIED</> </> </> . . . </>
[0029] As shown, the sample conflict notification includes the object id (shown as “ 123 ”) that has changed and a status (shown as “Read Flag Modified”) describing the type of change that occurred. In general, the conflict notification 382 provides sufficient information to the mobile device 320 such that the mobile device 320 may provide a suitable user interface (not shown) to the user regarding the conflict. The user interface may be implemented in any manner and will depend on how the application 266 (shown in FIG. 2) responsible for displaying the conflict information chooses to relay the conflict information to the user of the mobile device 320 . Because the specific user interface chosen is not pertinent to understand the present invention, the present discussion does not further describe the user interface on the mobile device 320 . The sample conflict notification shown above only includes the property that caused the conflict than the entire object. This embodiment increases the efficiency of the conflict resolution process when using wireless technology because less data is sent.
[0030] As will be described in greater detail below, the conflict manager 380 in accordance with the present invention, automatically resolves certain conflicts and provides sufficient conflict notification 382 to the mobile device 320 for a user to select how the conflict should be resolved using the user interface on the mobile device 320 when the conflict can not be automatically resolved. Thus, the present invention provides an efficient method for resolving conflicts in data objects during a synchronization session.
[0031] [0031]FIG. 4 is a graphical representation of one embodiment of the salient portions of a sample data object 400 that may be used as a server data object 314 or a mobile data object 324 in conjunction with present invention. The sample data object 400 includes an object id (OID) 402 , a plurality of properties P 1−N , and a change indicator 404 . The object id 402 may be a server ID (SID) if the object ID (OID) is stored on the server 310 or a device ID (DID) if the object ID is stored on the device 320 . As one skilled in the art will appreciate, after synchronization is complete, each SID typically has a corresponding DID on the mobile device to which it is mapped. The properties P 1−N store information associated with the data object based on the type of data object.
[0032] A representative data object is illustrated in FIG. 4 and represents an email message object. The illustrative properties for the email message object may include a recipient field P 1 , a sender field P 2 , a read flag field P 3 , a message text field P 4 , a subject field P 5 , a data last read field P 6 , a priority field P 7 , a follow-up flag field P 8 and any other information regarding the email message object. The change indicator 404 indicates when any the properties P 1−N of the data object 400 have changed. For example, if a user reads the email message, property # 4 (read property) is set to indicate read and the change indicator 404 is marked indicating that the data object 400 has changed in some way. When the change indicator 404 is so marked, the data object 400 is sometimes referred to as “dirty”. The data object 400 is considered “dirty” even if the user reads the email message and then sets the email message as unread (the value of property # 4 would, in essence, remain the same).
[0033] In accordance with the present invention, certain properties are also designated as syncable properties 406 . Syncable properties 406 are properties within the data object 400 that may be changed. Typically, properties that cannot be changed are not designated as syncable properties (e.g., the recipient field P 1 and the sender field P 2 ). However, these non-changeable properties may be designated as syncable properties without departing from the scope of the present invention. In addition, in accordance with the present invention, some of the designated syncable properties 406 are further designated as mergeable properties 408 (e.g., the read property P 3 ). As will be described in detail below in reference to FIGS. 5 - 7 , the conflict manager uses the change indicator 404 , the syncable properties 406 and the mergeable properties 408 when determining a “true” conflict and resolving the “true” conflict, in accordance with the present invention. By determining “true” conflicts in the manner described in the present invention, users do not receive unhelpful conflict messages and do not need to intervene each time both the mobile data object and the corresponding server data change.
[0034] [0034]FIG. 5 is a logical flow diagram generally illustrating an overview of a synchronization process having a conflict resolution process for resolving conflicts detected during a synchronization session. Briefly, the overview of the synchronization process shown in FIG. 5 detects whether a potential conflict, in accordance with the present invention, may exist and the manner in which the potential conflict is resolved during the synchronization process. The synchronization process with conflict resolution 500 begins at block 501 , where a synchronization session has been initiated and both the mobile device 320 and the information server 320 have sent client synchronization data 330 and server synchronization data 350 to the synchronization application 342 , respectively. The synchronization application 342 has passed the client synchronization data 330 and server synchronization data 350 to the conflict manager 380 for conflict processing. Processing continues at blocks 502 and 504 .
[0035] At blocks 502 and 504 , the conflict manager 380 gets one of the mobile data objects 324 (block 502 ) and a corresponding server data object 314 ( 504 ).
[0036] At block 506 , the conflict manager 380 checks the change indicator 404 associated with the corresponding server data object 314 to determine whether any changes have been made to the server data object 314 .
[0037] At decision block 508 , if the change indicator 404 associated with server data object 314 indicates that the server data object 314 is not “dirty” (i.e., no changes were made to any properties associated with the server data object 314 ), the process continues at block 510 .
[0038] At block 510 , the conflict manager 380 checks the change indicator 404 associated with the mobile data object 324 to determine whether any changes have been made to the mobile data object 324 .
[0039] At decision block 512 , if the change indicator 404 associated with the mobile data object 324 indicates that the mobile data object 324 is not “dirty” (i.e., no changes were made to any properties associated with the mobile data object 324 ), the mobile data object 324 and the server data object 314 are not synchronized because neither data object had updates. In one embodiment, either the mobile data object 324 or the server data object 314 will be “dirty”. This reduces the amount of data transmitted in the synchronization data because it insures at least one of the data objects has changed. If the mobile data object 324 is not “dirty” at decision block 512 , processing continues at decision block 514 .
[0040] At decision block 514 , the conflict manager 380 determines whether there are any more mobile data objects 324 and corresponding server data objects 314 . If some data objects 314 , 324 still remain to be processed, the process loops back to block 502 and proceeds as described above. However, once all the data objects 324 314 have been processed, the conflict resolution processing within the synchronization process is complete and the process ends at end block 516 .
[0041] Now, returning to decision block 508 , if the conflict manager 380 determines that the server data object is “dirty”, processing continues at block 518 and then to decision block 520 . At block 518 , the conflict manager 380 checks the change indicator 404 associated with the mobile data object 324 to determine whether any changes have been made to the mobile data object 324 . At decision block 520 , if the change indicator 404 associated with the mobile data object 324 indicates that the mobile data object 324 is not “dirty” (i.e., no changes were made to any properties associated with the mobile data object 324 ). If the mobile data object 324 is not “dirty”, this indicates that only one of the data objects is “dirty”. Thus, the data objects 314 324 may be synchronized using any well-known synchronization technique without performing the conflict resolution process of the present invention. Typically, the synchronization provided in block 522 attempts to update both data objects 314 324 to have identical information. Block 522 is also entered after a determination is made at decision block 512 that only the mobile data object 324 is “dirty”. Again, because only one of the data objects is “dirty”, synchronization is provided without performing the conflict resolution process of the present invention.
[0042] However, if both data objects 314 324 are “dirty”, as determined at decision blocks 508 and 520 , processing continues to block 524 . Briefly, at block 524 , the conflict manager determines the extent of the conflict between the mobile data object 324 and the server data object 314 and attempts to resolve the conflict with as little user intervention as possible. A detailed description of the conflict resolution process is illustrated in FIG. 6 and described below. Processing then continues to decision block 514 and proceeds as described above.
[0043] [0043]FIG. 6 is a logical flow diagram illustrating one embodiment of a conflict resolution process 600 suitable for use in FIG. 5. The conflict resolution process 600 begins at block 601 , after the conflict manager 380 has determined that there is a conflict between a mobile data object 324 and a corresponding server data object 314 . Processing continues at decision block 602 .
[0044] At decision block 602 , a determination is made whether the change indicator 404 indicates that the server data object 324 was “dirty” because the server data object 314 has been deleted. If the server data object 314 has been deleted, processing continues to block 604 . At block 604 , the conflict manager instructs the synchronization application 342 (FIG. 3) to delete the corresponding mobile data object 324 . The synchronization application 342 may then include the appropriate information in the client synchronization data 330 sent to the mobile device 320 at some later time. The synchronization application may include the information in the current synchronization session or in a later synchronization session. Processing continues to return block 606 and back to FIG. 5.
[0045] Returning back to decision block 602 , if the server data object 314 has not been deleted, processing continues to decision block 608 . At decision block 608 , a determination is made whether the change indicator 404 for the mobile data object 324 indicated that the mobile data object 324 was “dirty” because the mobile data object 324 has been deleted. If the mobile data object 324 has not been deleted, processing continues at block 610 . At block 610 , the conflict manager instructs the synchronization application 342 (FIG. 3) to delete the corresponding server data object 314 during one of the synchronization sessions. Processing continues to return block 606 and back to FIG. 6.
[0046] Returning back to decision block 608 , if the mobile data object 324 has not been deleted, processing continues at block 612 . At block 612 , the properties of the mobile data object 324 and the server data object 314 that were designated as syncable properties are compared. As mentioned earlier, by specifying only certain of the properties as syncable properties 406 , the present invention decreases the number of conflicts that are reported compared to prior conflict resolution methods. In addition, the conflict resolution process, in accordance with the present invention, is able to automatically resolve these “true” conflicts based on the syncable properties without user intervention in certain situations. Processing continues to decision block 614 .
[0047] At decision block 614 , a determination is made whether any of the syncable properties indeed differ. If none of the syncable properties differ, processing continues to block 616 , where the change indicator 404 for both the mobile data object 324 and the server data object 314 are reset to indicate that the corresponding object is not “dirty.” Thus, in accordance with the present invention, the user of the mobile device 320 does not receive an unintelligible conflict message due to changes in the data objects 314 324 that do not warrant user concern. For example, if only the “Read” property has been changed from unread to read on both objects, even though both messages are “dirty,” the information is the same and the user need not be informed. Processing continues to return block 606 and back to FIG. 6.
[0048] Returning back to decision block 614 , if it is determined that syncable properties differ, processing continues to decision block 618 , where the syncable property is retrieved.
[0049] At block 620 , a determination is made whether all the syncable properties that differ can be resolved using the simple merge process. This determination is based on whether the syncable properties that differ are also designated as mergeable properties 408 (FIG. 4) in the data objects. If any of the syncable properties that differ are designated as a mergeable property, the process continues at block 624 .
[0050] At block 624 , a simple merge process is performed. In accordance with the present invention, each property designated as a mergeable property has an associated pre-determined preferred state for the property. In one embodiment, the preferred state is related to the likelihood that vital information would be lost if the property of the data object was not changed to the preferred state. In another embodiment, the user on the mobile device may specify the preferred state for the property designated as a mergeable property. During the simple merge process the preferred state for the property is pushed to the data object with the property in a state different than the preferred state. A beneficial effect on resolving the conflict using the simple merge process is that the user is not inconvenienced by an unintelligible conflict message that requires user-intervention and that the user does not lose vital information. Below are two tables summarizing the outcome of processing from block 624 . Table 1 summarizes the simple merge process (block 624 ) for conflicting email objects in which “UNREAD” is the preferred state. Table 2 summarizes the simple merge process (block 624 ) for conflicting appointment objects in which “POSTPONE” or “POSTPONE to earliest time” is the preferred state.
TABLE 1 Starting State User Action State After Change Simple Merge Changes (Synched) (Disconnected) (Disconnected) (N/C = No Change) Server Device Server Device Server Device Server Device READ READ Marks Mail Marks Mail UNREAD READ UNREAD, Change to As As N/C UNREAD; UNREAD UNREAD, Send conflict then READs status to device mail READ READ Marks Mail Marks Mail READ READ READ, N/C READ, N/C As As UNREAD, UNREAD, then then READs READs it it READ READ Marks Mail Marks Mail READ UNREAD Change to UNREAD, N/C As As UNREAD UNREAD, UNREAD then READS it UNREAD UNREAD READs READs UNREAD READ UNREAD, Change to mail then Mail N/C UNREAD; Marks As Send conflict UNREAD status to device UNREAD UNREAD READs READs UNREAD UNREAD UNREAD, UNREAD, N/C mail, then mail, then N/C Marks As Marks As UNREAD UNREAD UNREAD UNREAD READs READs READ UNREAD Change to UNREAD, N/C Mail mail, then UNREAD Marks As UNREAD
[0051] [0051] TABLE 2 Starting State User Action Simple Merge Action Performed (Synched) (Disconnected) (N/C = No Change) Server Device Server Device Server Device Reminder Reminder Dismiss Dismiss N/C N/C ON ON Reminder Reminder Dismiss Postpone for Change to N/C ON ON X minutes Postpone for X Minutes Reminder Reminder Postpone for Dismiss N/C Change to Postpone ON ON X minutes for X Minutes; send conflict property to device Reminder Reminder Postpone Postpone N/C N/C ON ON until X:00. until X:00. Reminder Reminder Postpone Postpone Sync the Sync the change that ON ON until X:00. until Y:00. change that re- reminds the user the minds the user earliest; send the earliest. conflict property to device.
[0052] After the simple merge process is completed, processing continues at block 626 .
[0053] At block 626 , a conflict notification for the above syncable property is prepared. As described earlier, the conflict notification provides sufficient information that the mobile device 320 may display a user interface with the information if desired. In one embodiment, only the property causing the conflict is sent to the mobile device rather than the entire data object. Processing continues to return block 606 and back to FIG. 5.
[0054] Returning to decision block 620 , when all the syncable properties that differ cannot be resolved using a simple merge process, processing continue to block 622 . At block 622 , a user-selectable conflict resolution process is performed based on a conflict resolution method selected by the user of the mobile device 320 . Briefly, in one embodiment, a user may request one of three conflict resolution methods: client wins, server wins, or keep both. The user of the mobile device 320 selects the method using one of the input devices 112 available on the mobile device, such as a keypad. The appropriate program module 106 will then include the parameter 322 that specifies the selected method within the synchronization data 330 sent to the synchronization application 342 . The synchronization application 342 will provide the parameter 332 to the conflict manager 380 . The technique used to specify the selected method for conflict resolution and pass the information to the conflict manager 380 may be achieved using various techniques known with the art and which do not involve undue experimentation. The user-selectable conflict resolution is illustrated in FIG. 7 and described below in detail. Processing continues to return block 606 and back to FIG. 5.
[0055] [0055]FIG. 7 is a logical flow diagram illustrating one embodiment of a user-selectable conflict process 700 suitable for use in FIG. 6. The user-selectable conflict resolution process 700 begins at block 701 , after there has been a determination that a simple merge process is not available for resolving the conflict between the mobile data object 324 and the corresponding server data object 314 . Processing continues at decision block 702 .
[0056] At block 702 , a determination is made whether the user of the mobile device 320 chose the “client wins” method. If the “client wins” method was chosen, processing continues at block 704 . At block 704 , the server data object 314 is replaced with the mobile data object 324 . One skilled in the art will appreciate that the replacement of the data object may occur immediately or at some later time during the synchronization session or a later synchronization session. Processing continues to return block 718 and back to FIG. 6.
[0057] Returning to block 702 , if the user did not chose the “client wins” method, processing continues to decision block 706 . At decision block 706 , a determination is made whether the user selected the “server wins” method. If the “server wins” method is chosen, processing continues to blocks 708 and 710 . At block 708 , a copy of the server data object 314 is sent to the mobile device 320 . At block 710 , the mobile data object 324 is replaced with the server data object 314 . Again, the actual replacement of the mobile data object 324 may occur at anytime during the synchronization session or may occur during a later synchronization session. Processing continues to return block 718 and back to FIG. 6.
[0058] Returning to block 706 , if the user did not chose the “server wins” method, the default method “keep both” is performed. Processing continues at blocks 712 - 714 . At block 712 , a copy of the server data object 314 is sent to the mobile device 320 . At block 714 , the prior mobile data object 324 is sent to the server as a new data object during the next synchronization session. Processing continues to return block 718 and back to FIG. 6.
[0059] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A system and method is described for resolving a conflict detected while synchronizing a first data object in a first store associated with a mobile device and a second data object in a second store associated with a server. Once the conflict is detected, properties of the first data object are compared with corresponding properties of the second data object. If the properties and the corresponding properties that differ are designated as mergeable properties, the properties and the corresponding properties are merged. Merging the properties involves sending a preferred state associated with each of the properties and the corresponding properties to the mobile device and the server for updating the first data object and second data object, respectively, when an initial state for the properties and the corresponding properties is different than the preferred state. The preferred state is based on a likelihood that vital information would be lost if the preferred state did not replace the initial state of the property or the corresponding property. The merging is performed without user-intervention on the mobile device. In addition, the entire first data object or second data object is not sent to the mobile device to achieve the merge, thereby minimizing the data transfer to the mobile device.
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This is a division of application Ser. No. 07/537,201 filed Jun. 12, 1990 now U.S. Pat. No. 5,090,978, granted Feb. 25, 1992 which is a continuation of application Ser. No. 07/238,373 filed Aug. 30, 1988 now abandoned.
TECHNICAL FIELD
This invention relates to apparatus for heating glassy tubes. More particularly, this invention relates to apparatus to facilitate collapse of an optical preform tube into a preform from which optical fiber is drawn.
BACKGROUND OF THE INVENTION
There are several different techniques for producing optical fiber for use in communications. One such technique comprises directing a constantly moving stream of reactants and oxygen through a glass substrate tube having a generally circular cross-section. The oxygen stream carries silicon tetrachloride and dopants to produce the desired index of refraction in the finished optical fiber. The substrate glass is heated to a reaction temperature within a moving hot zone that traverses the length of the tube, and the consequent reaction produces doped silicon dioxide fused into a continuous layer on the inner wall of the tube. The resulting tube is referred to as a preform tube. See for example, U.S. Pat. No. 4,217,027 which issued on Aug. 12, 1980 in the names of J. B. MacChesney and P. B. O'Connor.
A torch assembly for heating a glass substrate tube to facilitate deposition of the reactants in the above-described process is described in U.S. Pat. No. 4,231,777 which issued on Nov. 4, 1980, in the names of B. Lynch and F. P. Partus. See also U.S. Pat. No. 4,401,267 which issued on Aug. 30, 1983 in the name of C. D. Spainhour. Initially, one end of the tube is supported in the headstock of a lathe and the other end is welded to an exhaust tube that is supported in the tailstock. Combustible gases are directed through a housing and gas outlets of the torch assembly and toward the tube as it is turned rotatably about its longitudinal axis and as the torch assembly is moved therealong on a carriage to produce a moving hot zone. A temperature profile is produced across the hot zone which moves along on the surface of the tube to accomplish the desired reaction and deposition. See F. P. Partus, and M. A. Saifi "Lightguide Preform Manufacture" beginning at page 39 of the Winter 1980 issue of the Western Electric Engineer.
During a deposition mode, the torch carriage moves slowly from the headstock of the lathe where dopants are moved into the glass tube to the tailstock where gases are exhausted. At the end of each pass from headstock to tailstock, the torch carriage is returned rapidly to the headstock for the beginning of another cycle. The ends of the gas outlets adjacent to the tube are cooled to eliminate substantially degradation by oxidation or reduction, for example, of the material forming the housing and gas outlets. In one embodiment of this technique, a plasma is established in the tube to enhance certain processes in reaction and deposition.
Subsequent to the deposition mode, a collapse mode is used to cause the preform tube to become a solid rod-like member which is called a preform. It is this preform from which lightguide fiber is drawn. See D. H. Smithgall and D. L. Myers "Drawing Lightguide Fiber" beginning at page 49 of the hereinbefore identified Winter 1980 issue of the Western Electric Engineer.
In order to collapse the preform tube, the torch assembly is moved in a number of passes from the headstock to the tailstock and then in a plurality of passes from the tailstock to headstock. The temperature of the moving hot zone which is higher during the collapse mode than during the deposition mode softens the tube wall and allows surface tension to cause the tube to collapse into a rod. During the collapse mode, straightening methods disclosed in U.S. Pat. No. 4,477,273 which issued on Oct. 16, 1984 in the names of B. Lynch and F. P. Partus may be used to cause the resultant preform to be substantially straight. The process of collapsing a preform tube may consume as much time as four and one-half hours.
There has long been a desire to reduce the time required to collapse a preform tube into a preform. A solution to this problem will yield significant dividends as the costs are directly proportional to the time required for this step.
Seemingly, the prior art is devoid of a solution to this problem. Techniques have been proposed but none has met wide acceptance. An acceptable solution to this problem which should be able to be used with present straightening techniques should yield a lower cost preform having exceptional straightness.
SUMMARY OF THE INVENTION
The foregoing problem of the prior art has been solved by the apparatus of this invention. A method of heating a tube to induce its collapse includes the step of supporting the tube at its ends for rotation about a longitudinal axis thereof. An outer surface of the tube is heated by directing a flow of gases through a torch assembly toward a portion of the length of the tube. Each successive increment of length of the tube is exposed to a zone of heat having a temperature profile by causing relative motion between the zone of heat and the tube while the tube is being rotated. As the tube is rotated, it is collapsed into a solid rod as the heat energy is confined and directed in a narrow band into engagement with the tube. At least a substantial portion of the zone of heat is confined about substantially the entire circumference of the tube along a portion of the length of the tube. The heat energy is confined by a muffle tube which overhangs at least one side of the torch assembly and which encloses the circumference of that portion of the tube which extends through the torch assembly and an additional portion of the tube which extends beyond the torch assembly. Gases are caused to be directed from the torch assembly into engagement with the portion of the length of the tube in a manner which results in a relatively narrow maximum temperature portion of the zone of heat. This is accomplished by causing the flow paths of the gases as they emerge from passageways of the torch assembly to be confined laterally for a predetermined distance.
In the manufacture of a preform tube from which optical fiber is drawn, a substrate tube, having a generally circular cross-section, is supported rotatably at its ends. The substrate tube is turned rotatably and heated to an initial temperature while doped reactants are deposited in the tube to form a predetermined profile. During deposition, the temperature of the tube is increased from the initial temperature as the number of passes increase. Then, the outer surface of the tube is heated to a temperature within a range which is higher than the initial temperature by the moving zone of heat and the tube is collapsed into a rod in accordance with the foregoing method. Afterwards, optical fiber is drawn from the rod.
In an apparatus for collapsing an elongated glass preform tube having a circular cross-section and a deposited core, facilities are provided for holding ends of the tube to allow rotation about its longitudinal axis. The apparatus includes a torch for heating the preform tube. Relative motion is caused between a zone of heat which is produced by the torch and the preform tube in a plurality of passes to cause successive increments of the length of the tube to be heated while it is turned rotatably.
The heat energy provided by the torch is confined by a muffle tube which encloses the preform tube from one side of the torch to the other for a predetermined distance on that side of the torch which is the trailing side during an initial portion of the deposition mode.
Further, the torch is modified to optimize the application of the maximum temperature portion of the heat zone. This is done by recessing a center portion of the torch which includes exit ports for the combustible gases with respect to portions contiguous thereto, thereby causing the heat zone to be narrowed. As a result, the heat energy is somewhat confined and is more concentrated. The use of the muffle tube in cooperation with the partial confinement of the flow paths of the gases causes collapse in a substantially shorter period of time than with prior art apparatus.
BRIEF DESCRIPTION OF THE DRAWING
Other features of the present invention will be more readily understood from the following detailed description of specific embodiments thereof when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an arrangement which is used to deposit layers of glassy materials on an inner wall of a glass substrate tube to provide a preform tube and for then causing the tube to be collapsed into a preform from which optical fiber is drawn;
FIG. 2 is a view of a portion of a torch assembly, a portion of a straightening device and a temperature profile across a zone of heat which traverses the tube;
FIG. 3 is a perspective view of a torch assembly comprising a muffle tube which encloses that portion of the preform tube that extends through the torch assembly and which extends to one side of the torch assembly and also comprising provisions for narrowing the zone of heat;
FIG. 4 is an exploded perspective view of portions of the torch assembly; and
FIGS. 5 and 6 are alternative embodiments of the muffle tube.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown an apparatus, designated generally by the numeral 30, for heating and collapsing a glass tube to manufacture a solid silica glass preform from which a optical fiber is drawn. During a deposition mode, a substrate tube 31 is heated in order to cause the reaction products of gases and/or dopants being fed into the tube to be fused to the inside wall thereof to provide a preform tube having an optically suitable profile for communications use. In this description, the numeral 31 is used to designate both the substrate tube and the preform tube. The heating of the glass tube 31 is carried out while gas phase reactants are delivered to the tube. A system for this delivery is disclosed in U.S. Pat. No. 4,276,243 which issued on Jun. 30, 1981, in the name of F. P. Partus.
The apparatus 30 generally comprises a lathe 32 having a headstock 33 and a tailstock 34 which are used to support the glass starting tube 31 for rotation about its longitudinal axis 36. The lathe 32 also includes a carriage 40 which is mounted for reciprocal movement along the lathe. Mounted on the carriage 40 is a torch assembly which is designated generally by the numeral 50 and a collapsing device which is designated by the numeral 51.
The torch assembly 50 is adapted to cause a flow of combustible gases to produce flames which are directed toward the tube 31. By confining the heat from the burning gases to a desired surface area of the tube, the torch assembly 50 establishes a zone of heat 54 (see FIG. 2) having a temperature profile 55 at the surface of the tube. The mounting of the torch assembly 50 on the carriage 40 and its movement relative to the tube 31 causes the zone of heat, which may be referred to as a hot zone, to be moved along the length of the tube. The torch assembly 50 is supported by a bracket 53 which is supported from a post 57 that is mounted on the carriage 40. Through adjustment of the bracket 53, the torch assembly 50 may be moved within any one of a range of distances from the tube 31 or to any one of a plurality of positions about and spaced from the tube.
The torch assembly 50 is described in relation to its use for heating glass tubes as material is deposited on the inside surface thereof and to provide elevated temperatures to collapse such tubes. However, such description is for purposes of exposition and not for limitation for the instant torch assembly may be used advantageously to heat other articles having various geometries.
The torch assembly 50 in the perspective and exploded views shown in FIGS. 3 and 4 is comprised of first and second identical outer plate-like members 62 and 64, respectively, and a gas outlet plate 66, with the outer members having coextensive arcuate surfaces. The outer members 62 and 64 each have an arcuately shaped plenum 68 and an input conduit 72 communicating therewith. Also, the first and second outer members 62 and 64 each have a channel 74 connected to a connecting conduit 75 and to a cooling tube 76. A plurality of threaded holes 78--78 pass through the member 62 and a plurality of holes 79 pass through the member 64. The gas outlet plate 66 includes an inner arcuate surface 80.
As can be seen in FIGS. 3 and 4, the gas outlet plate 66 has a first plurality of radially disposed grooves or slots 82--82 machined in a first major surface 84 and a second plurality of radially disposed grooves or slots 86--86 machined in a second major surface 88. The grooves 82 and 86 open to the surface 80. The gas outlet plate 66 also has a plurality of holes 92--92 therethrough which become aligned with the holes 78--78 and 79--79 of the outer members 62 and 64 when the outer members are assembled with the gas outlet plate.
FIG. 3 is a perspective view of the torch assembly 50 which is assembled by capturing the planar gas outlet plate 66 between the outer members 62 and 64 and securing the component parts together with a plurality of bolts 94--94 which pass through the holes 78, 79 and 92. It can be seen from FIG. 3 that the planar gas outlet plate 66 separates the two plenums 68--68 and that the radial lengths of the grooves is sufficient to communicate from the vicinity of arcuate outer surfaces 96 and 98 of the torch assembly 50 to the plenums 68--68 of members 62 and 64, respectively. Although in an embodiment shown in FIGS. 3 and 4, the grooves 82 and 86 are interleaved, other arrangements such as aligned grooves or offset grooves can be used effectively depending on factors, such as, for example, the gases used, the surface mixing required, and the desired temperature.
In a particular exemplary embodiment depicted in FIG. 3, the outer members 62 and 64, as well as the plate 66, were made of stainless steel and the tubing 76 was made of stainless steel. Of course, other suitable materials may be used.
In operation, a substrate tube 31 is supported by the headstock 33 and the tailstock 34 of the lathe 32 and is caused to be rotated. Then oxygen is directed into the plenum 68 of the outer member 62 via the conduit 72 while hydrogen is flowed into the plenum 68 of the outer member 64 via the conduit 72. The oxygen and the hydrogen gases are caused to pass from the plenums 68--68 and exit through the grooves 82 and 86, respectively, as alternating jets. The gases will mix at the surface 80 of the torch assembly 50 and are ignited to form a flame which is directed into engagement with the tube 31. The torch assembly 50 is moved repeatedly along the length of the substrate tube in a plurality of passes from the headstock 33 to the tailstock 34 to provide sufficient heat to fabricate an optical preform as described in detail in U.S. Pat. No. 4,217,027 which is incorporated by reference hereinto. A coolant, such as water, is passed through each tube 76, to maintain the temperature of the arcuate surface 80 low enough to prevent oxides from forming on the surface thereof to prevent subsequent ejection of particulate matter which can contaminate the surface of the preform during fabrication. Such particulate matter can adversely affect the strength of a fiber drawn therefrom. Although, the instant embodiment of each outer plate is connected to a coolant tube 76, various other techniques may be used. Also, although the exemplary torch assembly provides an oxygen-hydrogen mixture, other suitable gas combinations can be used.
Typically, the chemical materials for deposition are supplied to the substrate tube at its headstock end. Gases are exhausted at the tailstock end. In a deposition mode, the torch is moved in a plurality of passes from the headstock toward the tailstock.
After the deposition mode, the torch assembly is moved initially in two passes from the headstock 33 to the tailstock 34 in a collapse mode. During the collapse mode, the flow rates of the gases are increased substantially. Then the exhaust end of the preform tube is pinched off and the torch assembly moved in a pass from the tailstock to the headstock. Further as can be seen in FIG. 1, the straightening device 51 is provided with a roller 90. The roller 90 is moved into engagement with the preform tube at predetermined times during the collapse mode such as after the initial two passes of the collapse mode to cause the tube to be straightened. Such a roller and its operation are described in priorly mentioned U.S. Pat. No. 4,477,273 which is incorporated by reference hereinto. Subsequently, two additional passes are made from the tailstock to the headstock to complete the collapse of the preform tube into a preform rod having a diameter in the range of from about 16.5 mm to about 18.1 mm. From this rod, optical fiber is drawn. See U.S. Pat. No. 4,370,355, which issued on Jan. 25, 1983 in the name of P. J. Niesse and which is incorporated by reference hereinto.
The apparatus 30 of this invention includes additional features which cooperate with the portion of the apparatus described thus far to reduce the collapse time. The torch assembly includes a muffle tube 100 which is supported by the outer members 62 and 66 with an inner surface 102 of a portion 104 thereof being somewhat of a continuation of inner surfaces 96 and 98 of the outer plates. The muffle tube 100 includes an opening 105 to provide access to the preform tube for a pyrometer 106. An outer peripheral surface 109 of the muffle tube 100 has a radius greater than the inner radii of the outer torch members 62 and 64 with radial surfaces of the one portion 104 of the tube engaging radial portions 111 and 113 of the outer members.
Another portion 115 of the muffle tube 100 extends from the one portion 104 toward the headstock 33 and overhangs the outer member 64. It is supported by brackets 117--117 which are held in position by straps 119--119. The length of the overhang is determined as a function of carriage speed and the desired temperature profile of the heat zone 54.
It is preferred that the muffle tube overhang only that side portion of the torch assembly 50 which is oriented toward the headstock 33. This is required so that during relatively high speed passes when the maximum temperature portions of the heat zone 54 experience a maximum lag from the centerline of the torch, the maximum temperature portion will be enclosed by the muffle tube.
Overhang of the muffle tube also is important with respect to the amount of useable preform tube provided by the process of this invention. The useable portion of the preform tube begins several centimeters from the headstock. As a result, although an overhang of the torch assembly 50 at its headstock side prevents the torch assembly from engaging the headstock on each pass, this does not decrease the amount of useable preform. At the other end however, the useable preform begins at the tailstock. Therefore, if anything such as a muffle tube extension prevents the torch assembly from reaching the tailstock on each pass, there would be a reduction in the amount of useable preform. The magnitude of the reduction depends of course on the amount of the overhang, if any, on the tailstock side of the torch assembly.
The torch assembly 50 is configured to optimize the application of the zone of heat to the preform tube to collapse the tube into a preform rod. As can be seen in FIGS. 1 and 3, the arcuate surface 80 of the middle plate 66, that is the plate which is slotted to provide egress for the gases, is recessed between the outermost members 62 and 64. In other words, the radius of the innermost surface 80 of the slotted plate 66 is greater than the radii of the innermost surfaces of the outer members. In a preferred embodiment, the radius of the slotted plate of a conventional torch is increased by about 0.15 cm. In the preferred embodiment, the inner radius of each outer member 62 and 64 is 3.44 cm whereas the inner radius of the gas outlet plate that is, the radius to the surface 80 of the gas outlet plate to which the slots open is 3.59 cm.
A recessed gas outlet plate 66 in cooperation with the muffle tube 100 has been found to be advantageous both during deposition and collapse. As a result of the recessing, the maximum temperature portion of the heat zone is narrowed and hence is more concentrated than that of the prior art. During deposition, the flow rates of the gases are substantially less than during the collapse mode. This together with the muffle tube causes the zone of heat to be widened. However, during collapse, increased flow rates result in a narrow zone of heat. Also, the narrower the heat zone, the more controlled is the temperature profile and the less the time required to collapse the substrate tube.
In the operation of the apparatus 30 in a collapse mode, it is usual to use a first collapse pass in which the torch assembly is moved from the headstock toward the tailstock at a speed of 7.80 m/min. A second pass in the same direction is accomplished at a speed of 6.60 m/min. Third, fourth and fifth passes in an opposite direction, that is from the tailstock toward the headstock, are caused to occur at speeds of 4.8, 3 and 3 m/min, respectively.
At the higher speeds of the first two passes, the maximum temperature of the heat zone profile (see FIG. 2) lags the portion of the heat zone disposed between the two outer torch members 62 and 64. However, inasmuch as the muffle tube overhang is disposed on that side of the torch assembly 50 which is oriented toward the headstock, the maximum portion of the heat zone occurs within the overhanging portion of the muffle tube. As a result, maximum heat energy continues to be confined within the muffle tube circumferentially about the tube 31 notwithstanding the speed of the carriage 40. Hence the muffle tube 100 is effective to concentrate the heat energy to be applied to that portion of the tube which is disposed within the muffle tube.
In the last three passes during collapse, the carriage speed is less than during the first two. Therefore, even though the overhanging portion of the muffle tube 100 is disposed during those passes on the leading side of the torch assembly, the lag of the temperature profile from a symmetrically disposed profile is not that great. As a result, even during these passes, the zone of heat is confined substantially within the muffle tube 100.
The recessed gas outlet plate cooperates with the muffle tube 100 and its overhanging portion 115 to maximize the applied heat energy at the carriage speeds disclosed. It has been found that the amount by which the gas outlet plate is recessed is critical. If too little or if too much, the resulting preform may include excess curvature. It has been found that a recess on the order of about 0.15 cm is preferred and provides the best results.
What is important is the cooperation among the carriage speed, the amount of recess of the slotted plate 66 and the length of the muffle tube 100. One or all of these variables may be changed in order to control the temperature profile of the zone of heat and the time required in order to cause the preform tube to become collapsed into a preform rod. It has been found that the use of the methods and apparatus of this invention reduces the time required to collapse the preform tube into a rod by about twenty-five percent.
For the deposition mode, the heat zone is about the same as that found during deposition with a torch not having a muffle tube nor a recessed gas outlet plate. On the other hand, the use of a torch assembly having a muffle plate and recessed gas outlet plate allows the use of lower flow rates for the gases during deposition, thereby resulting in significantly lower gas consumption. Nevertheless, even though the flow rates are lower, the muffle tube reradiates heat energy and causes the heat zone to be about as broad as without the muffle tube and recess.
As mentioned earlier, the recessed gas outlet plate results in a narrowed heat zone. The relatively narrow heat zone cooperates with the muffle tube to provide higher temperatures. Further, during collapse, the gas flow rates are substantially greater than those used during deposition, but approximate those used for a torch not having a recessed gas outlet plate and muffle tube. Because of the cooperation among the narrower heat zone, the muffle tube and the higher flow rates, the forces of the gases on the preform tube are greater. This reduces the collapse time by about twenty-five percent.
The torch assembly 50 may be repaired simply by replacing any of the three basic components, i.e., the outer members 62 and 64 and the gas outlet plate 66. Furthermore, the heat zone and the flame pressure areas provided by the torch assembly 50 may be modified by simply changing the size of the grooves 82 and 86 and/or the thickness of the gas outlet plate 66 and or by the amount by which the gas outlet plate is recessed.
Although the muffle tube 100 in the preferred embodiment is caused to overhang one of the outer members 62 or 64, other embodiments may be used. In FIG. 5 is shown a muffle tube 120 which overhangs both side members 62 and 64. Remembering that the side member 64 is oriented toward the headstock, the overhang of the muffle tube 120 from the side member 64 may be greater than that past the side member 62.
In FIG. 6, there is shown another embodiment of a muffle tube. Therein a muffle tube 130 is caused to extend only from an outer surface of one side member 62 to an outer surface of the other side member 64. The muffle tube 130 is held in position by clamps 132--132.
It is understood that the above-described arrangements are simply illustrative of the invention. Other arrangements may be devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.
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A preform tube (31) is caused to be collpased into a preform rod by causing a heat zone (54) provided by a torch assembly (50) to traverse the tube longitudinally in a plurality of passes. During this so-called collapse mode, a muffle tube (100) encloses that portion of the tube which extends through the torch assembly. Advantageously, the muffle tube projects a predetermined distance beyond one major face of the torch assembly. The torch assembly comprises annular semi-circular end plates and as annular semi-circular center portion having a plurality of exit ports through which gases are directed into engagement with the tube. The center portion is caused to be recessed between the end plates thereby causing the heat zone generated by the gases to be narrowed. The narrowing of the heat zone and the substantial confinement of the heat energy within the muffle tube cooperate with increased gas flow rates to cause the tube to be collapsed in a time period which is substantially less than that achieved by prior art methods.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
FIELD OF INVENTION
[0002] The present invention relates to a device designed for protecting the surrounding area where a surgically implanted port or medical “portacath” device is located. The Port Protection Device would protect the chest and port from damage or injury during daily physical activities and sports. It would be capable of being placed over different areas on the upper or lower chest depending on the placement of the port. More specifically, the present invention relates to protective apparatus suitable to provide users of port protection devices from impacts due to applied or external forces.
FEDERALLY SPONSORED RESEARCH
[0003] None.
SEQUENCE LISTING OR PROGRAM
[0004] None.
BACKGROUND
Field of Invention and Prior Art
A. Problem Addressed
[0005] As far as known, there are no special port protection devices in prior art like this one shown herein. It is believed that this product is unique in its design and technologies. The solution is driven primarily to aid children who use surgically implanted port devices and struggle with fear of getting hurt due to contact or impact to that area. Many of these children are capable of playing sports and desire to participate but they run the risk of injury to the area during the activity.
[0006] The port protector allows children, adolescents and adults to live normal lives and participate in physical activities. The children may participate in gym classes, playing with friends, or engaging in sports. Children with implanted ports tend to refrain from sports and strenuous physical activity due to the potential impact to the port area. There is chance of significant pain involved with impact as well as simply an object touching the port. A common condition children with implanted ports are experiencing is called “port walk”, where a child deliberately walks hunched over in an attempt to “protect the port and port area” from impact or touch resulting in pain. One notes that the use with children is fully anticipated but is not a limitation. Adolescents and adults may also benefit from the new device. They too may participate in physical activities, exercise and sporting events with the knowledge that the port and surrounding area is protected from impacts.
[0007] The port protector would be manufactured in standard off-the-shelf sizes and not need to be custom made for individual users. The early prototypes have focused primarily on the needs of children, but the concept extends as well for others as previously stated above.
B. Prior Art
[0008] Prior Art for similar devices are limited since this is a relative unique device. A chest protector was taught by Moschetti, et al in a U.S. Pat. No. 5,245,706 issued in 1993. It shows a protective device for the chest for use in athletic activities such as baseball, softball and hockey. It is a sternum pad made of heavier materials and held by straps. It does not have the absorption materials or configuration of the present port protector nor can it be placed in various locations over the portacath. Another protective garment device is demonstrated in U.S. Pat. No. 5,621,914 issued to Ramone et al in 1997. Here is taught a shirt device without the straps, location manner, or absorption pad stressed by the Suarez port protector.
[0009] An Apparatus and method to protect an implanted medical device or wound was provided in the U.S. Pat. No. 6,576,808 as a US patent issued to Dreyer in 2003. Dreyer describes a soft donut shaped pad intended to be used in a vehicle. It does not function or anticipate the instant port protector since it has no transportability with the user during physical activities. A U.S. Pat. No. 8,220,079 issued to Syska et el in 2012 showed a device called a “Portacath Protection Device”. It has three points of contact that would be adhered or attached to a protective shirt worn by the port user. This device does not show the adjustability and focused/specific use as demonstrated in the Suarez protective device.
[0010] A US Patent Application Publication No. 2009/0126087 by Armstrong et al shows an apparatus for protecting a pacemaker. It shows a raised dome but little ability to cover the chest area with straps directly over the portacath. It again uses a tee shirt for a medium to wear the device by the user. It lacks the function and fit of the Suarez port protector. Finally, heavier and bulky chest protectors have been shown for various sports, but the lack the specific location and lightweight feature of the present invention. One such example is the chest protector shown in U.S. Pat. No. 4,317,237 issued to Porte in 1982. Such devices as these lack the effectiveness of the new Suarez device.
BACKGROUND OF THE INVENTION
[0011] Persons undergoing intensive medical treatment may be required to have repeated and recurring medical infusion of drugs and hormones, or multiple drawing of blood samples. To ease patient discomfort associated with repeated needle sticks, the patient may elect to have a port surgically implanted beneath the skin. Medical conditions requiring frequent extended intravenous infusion that use ports include but are not limited to Cancer, Hemophilia, CVID, and Cystic Fibrosis, among others. Another device commonly used for frequent infusions is a PICC-Line (peripherally inserted central catheter). This too may be protected within the spirit and scope of the innovation presented here.
[0012] Various types of ports are currently available from manufacturers such as Porta-Cath, Microport, Bardport, PowerPort (power injectable), Passport, Infuse-a-Port, Medi-Port, and Lifesite (for hemodialysis patients) from companies including Bard Access Systems, Navilyst Medical, Smiths Medical, MedComp, Rita Medical Systems and AngioDynamics. As more companies and variations of the implants evolve, this instant Port Protection Device may be easily adapted within the scope of the configuration and materials of the device presented herein to be used with the new port implants.
[0013] In medicine, a port (or portacath) is a small medical appliance that is installed beneath the skin.
[0014] A catheter connects the port to a vein. Under the skin, the port has a septum through which drugs can be injected and blood samples can be drawn many times, usually with less discomfort for the patient than a more typical “needle stick”. A port consists of a reservoir compartment (the portal) that has a silicone bubble for needle insertion (the septum), with an attached plastic tube (the catheter). The device is surgically inserted under the skin in the upper chest or in the arm and appears as a bump under the skin. It requires no special maintenance and is completely internal so swimming and bathing are not a problem. The catheter runs from the portal and is surgically inserted into a vein (usually the jugular vein, subclavian vein, or superior vena cava). Ideally, the catheter terminates in the superior vena cava, just upstream of the right atrium. This position allows infused agents to be spread throughout the body quickly and efficiently. (Reference Wikipedia).
[0015] Ports often have many different uses, such as parenteral nutrition, delivery of chemotherapy, delivery of coagulation factors, withdrawal of blood from patients requiring frequent blood tests, delivery of antibiotics, and delivery of medications. Since the port is surgically implanted under the skin, there is a risk that the persons having such a port may damage it during the course of daily physical activities, especially for sports activities and the like. During such physical activities, people who have a port sometimes experience pain when physical contact is made with their port. Persons with a port are at a risk of rupturing the structural sutures that hold the port in place. It is also possible that the catheter may be ruptured or torn loose.
SUMMARY OF THE INVENTION
[0016] The device is a port protection device. The device is mainly comprised of a plastic back plate with a silicone pad adhered underneath which is held in place against the chest of the child by using elastic straps and latching clasps. The silicone pad provides a consistent soft contact area with the skin and chest which distributes the impact over a large area, instead of a few localized points. This would reduce the possibility of pain or injury to the chest. The use of adjustable elastic straps with clasps allow the device be set tightly against the body and chest and not allow for movement of the device during sports and physical activity.
OBJECTS AND ADVANTAGES
[0017] There are several objects and advantages of the Port Protection Device. These advantages and benefits are listed below.
[0000]
TABLE A
Item
Object/Advantage
1
Protect the child or user
2
Protect the implanted device
3
Promote confidence of the user in physical activity
4
Is light and durable
5
Is easy to clean
6
Is simple to attach around the body/chest of the
child or user and requires no special tools
7
Is available in universal sizes and requires no
special customization to the user
8
Is comprised of readily available materials
[0018] Finally, other advantages and additional features of the present port protection device will be more apparent from the accompanying drawings and from the full description of the device. For one skilled in the art of medical and sporting protection devices and the like, it is readily understood that the features shown in the examples with this product are readily adapted to other types of protective devices for ports and other medical systems and devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the Port Protection Devices that are preferred. The drawings together with the summary description given above and a detailed description given below serve to explain the principles of the Port Protection Device. It is understood, however, device is not limited to only the precise arrangements and instrumentalities shown.
[0020] FIG. 1 is a front view of the present invention in use.
[0021] FIG. 2 is a back view of the present invention in use.
[0022] FIG. 3 is a cross section view of the present invention in use.
[0023] FIG. 4 is a front view of one embodiment of the present invention.
[0024] FIG. 5 is a rear view of one embodiment of the present invention.
[0025] FIG. 6 is a cross section view of one embodiment of the present invention.
[0026] FIG. 6A is an enlarged cross sectional view of one embodiment of the present invention.
[0027] FIG. 7 is a back view of a second embodiment of the invention.
[0028] FIG. 8 is a back view of a second embodiment of the invention in use.
[0029] FIG. 9 is a cross section view of a second embodiment of the present invention.
[0030] FIG. 10 is a cross section view of a third embodiment of the present invention.
[0031] FIG. 11 is a cross section view of a fourth embodiment of the present invention.
[0032] FIG. 12 is a front view with an embodiment showing front clasps for use with the device.
DESCRIPTION OF THE DRAWINGS
Reference Numerals
[0033] The following list refers to the drawings:
[0000]
TABLE B
Reference numbers
Ref #
Description
31
User/individual with the port
32
Port shield device
33
Means for securing such as a number of (elastic)
straps
34
Means for securing and adjusting length of the
strap 33 such as clasps, hooks, hook and loop
devices [Velcro ™) or equal
35
Skin surface of individual 31
36
Implanted Portacath device
37
Rigid back plate (still with resilience and
pliable)
38
Dome raised above the general surface of the
device
39
Pad-absorption material able to resist impact
and cushion force of impact
40
Cut out, hole, or recess
41
Top surface of fabric
41A
Bottom surface of fabric 41
41B
Top surface of fabric 41
42
Means for securing, such as an adhesive placed in
the inherent small gap between the top surface of
the pad 37 and the lower surface of the back plate
39
43
Apertures for venting
44
Slots in back plate 39 for straps 33
45
PICC Line (not shown)
46
Sports bra (cross) razor back type strap
47
Single solid component (assembly or integral
combination of pad 37 and plate 39 combination)
48
Hollow celled component (assembly or integral
combination of pad 37 and plate 39 combination)
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present development is a port protection device. Particularly this new idea and concept is a product that is related to a device designed for protecting the surrounding area where a surgically implanted port is located. The Port Protection Device would protect the chest and port from damage or injury during daily physical activities and sports. It would be capable of being placed over different areas on the upper or lower chest, and/or abdomen depending on the placement of the port.
[0035] The preferred embodiment is a port protection device essentially comprised of a rigid back plate with a top and lower surface; a pad made of resilient material with a top surface and a lower surface, the top surface of the pad contiguously placed next to the lower surface of the back plate with a small gap at the junction of the contiguous surfaces and the lower surface of the pad next to a skin of a user; a means to secure the lower surface of the back plate to the top surface of the pad; a plurality of straps with a length long enough and able to wrap around a chest of the child; and a means to attach the plurality of straps to the back plate wherein the device is placed on the skin of the child directly over the port.
[0036] There is shown in FIGS. 1-12 a complete description and operative embodiment of the Port Protection Device. In the drawings and illustrations, one notes that the Figures demonstrate the general configuration and use of this product. The various example uses are in the operation and use section, below.
[0037] The foregoing and other features of the present Port Protection Device will be more readily apparent from the following detailed description and drawings of the illustrative embodiments of the invention in which various embodiments of the present invention will be described in detail with reference to the drawings, where like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the claimed invention.
[0038] The phrase “in one embodiment” as used herein does not necessarily refer to the same embodiment, though it may. Furthermore, the phrase “in another embodiment” as used herein does not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.
[0039] The port shield device 32 is shown in FIGS. 1 through 12 . FIG. 1 shows a front view of a user 31 wearing the device 32 on his chest directly over the implanted Portacath device 36 or the like. The unit is held in place with means for securing such as a number of straps 33 . FIG. 2 shows one configuration of the straps 33 and clasps 34 on the back of a user 31 . These clasps 34 are one example of a means for securing and adjusting length of the strap 33 such as clasps, hooks, hook and loop devices [Velcro™), bra type clasps, or equal. Here the clasps 34 are along the back of the user. FIG. 3 shows a cross section of the device located on a subject which shows how the protection device 31 is placed on the skin 35 of the user 31 directly over the implanted port device 36 or PICC Line 45 . Straps 33 hold the device 31 securely in place against the chest or abdomen of the user 31 .
[0040] One embodiment of the device shown in FIGS. 4 through 6 and enlarged FIG. 6 A consists of a pad 39 adhered to a rigid back plate 37 . There would be a plurality of slots 44 cut into the back plate 37 . The entire device 32 is covered in an encasing adhesive fabric 41 . A plurality of straps 33 would be threaded through the slots 44 cut into the back plate 37 . The device is placed directly on the skin 35 and held in place by the elastic straps 33 . Clasps 34 attached to the straps 33 would allow adjustability to ensure a tight fight against the body 31 and prohibit movement or slippage of the device 32 . The overall dimensions of the protective device, excluding the straps, are nominally or approximately 4 inches wide by 5 inches high, by 12 millimeters thick. This is exemplary and not a limitation of the size or configuration. Other shapes and sizes are possible.
[0041] The back plate 37 may be formed of polyethylene plastic. It would be between 1 millimeter and 5 millimeters thick. Preferably the back plate 37 will be a resilient/pliable material that is capable of slight deflection on impact to as to absorb and diminish any force of the impact. Other materials may be used, but polyethylene plastic would be preferred for rigid yet pliable characteristics. The rigid, pliable material here might also include—for example and not as a limitation—other materials such as molded plastic, rigid urethane, nylon, sheet plastic, rigid pressed cardboard, thin gaged (meaning less than 10 gage) metal, and composite material. In addition, a slightly raised dome 38 would be formed into the back plate 37 to allow for the port to extent into it in the event of a frontal impact. The dome 38 would have a base diameter approximately a nominal ⅝ of an inch and a height of approximately 3/32 of an inch. There may be holes or apertures 43 drilled into the back plate 37 and dome 38 to allow for venting. (See also FIG. 11 ).
[0042] The pad 39 which is attached to the underside of the back plate 37 may be made of a material with a means for securing 42 such as a silicone with adhesive backing 42 . The pad 37 would have a top surface contiguous and positioned flatly against the lower surface of the back plate 39 . There would be an inherent small gap naturally between the top surface of the pad 37 and the bottom surface of the back plate 39 where the means for securing 42 would be placed. The pad 39 would have a thickness between approximately 5 millimeters and 15 millimeters. Silicone is the preferred material for the pad 39 as it does not pack-out and it maintains the same thickness on impact. Another option for the pad 39 might be foam, such as Poron® urethane or the like, as it is lighter than the silicone. The shock absorbing material may also anticipate foam (open or closed cell), other urethanes, nylon, natural rubber, synthetic rubber, composite material, in addition to the general foam, Poron® urethane, and silicone gel mentioned above. The pad may be round in shape or have varying configurations. There would be a cut out, hole, or recess 40 of the center of the pad 39 which would be located underneath the dome 38 to accommodate the implanted port device 36 . The recess or hole 40 would line up with the dome 38 on the back plate 37 . The base diameter of the aperture/hole 40 would be approximately a nominal 1¼ inches. The diameter of the top of the hole 40 would be approximately a nominal 3/32 of an inch.
[0043] One embodiment of the device would be coated in fabric 41 so as to not irritate the skin 35 . The fabric 41 would be attached to the device 32 with means 42 for securing such as an adhesive. The fabric 41 may have a variety of colors and styles for depending on the user 31 types. Colors and styles for boys could be different than colors and styles for girls.
[0044] There will be slots 44 cut into the back plate 37 and fabric coating 41 to allow for straps 33 . The straps 33 may be made of soft elastic material that will not irritate the skin. Two quick release plastic clasps 34 would be utilized for ease of installation. They would be located in the front or in the back.
[0045] Another embodiment of the invention for girls and women would utilize a sports bra razor back type strap 46 as indicated on FIG. 8 .
[0046] Another embodiment of the invention consists of a single solid component 47 as seen on FIG. 9 . This shows a single solid component (assembly or integral combination of pad 37 and plate 39 combination). This assembly/component 47 is constructed of molded plastic, vinyl, rigid foam or similar material. Other materials include molded plastic, rigid foam, urethane, nylon, natural rubber, synthetic rubber, and composite material. Still another embodiment of the invention consists of a similar single component/assembly of hollow construction 48 as seen on FIG. 10 made of the same materials as above.
[0047] FIG. 12 is a front view of the device 32 with an embodiment showing front clasps 34 for use with the device 32 . These clasps are a means for securing and adjusting length of the strap 33 such as clasps, hooks, hook and loop devices [Velcro™) or equal. Here the clasps 34 are along the front of the user near the plate 37 .
[0048] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it would be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
Operation
[0049] The port protection device has been described in the above embodiments. The manner of how the device operates is described below. The port protection device is essentially comprised of a rigid back plate with a top and lower surface; a pad made of resilient material with a top surface and a lower surface, the top surface of the pad contiguously placed next to the lower surface of the back plate with a small gap at the junction of the contiguous surfaces and the lower surface of the pad next to a skin of a user; a means to secure the lower surface of the back plate to the top surface of the pad; a plurality of straps with a length long enough and able to wrap around a chest of the child; and a means to attach the plurality of straps to the back plate wherein the device is placed on the skin of the child directly over the port.
[0050] The port protection device 32 is intended to be easily and quickly installed and removed by a user 31 . On the initial installation, the device is to be placed on the chest or abdomen directly over the implanted port device 36 and held in place by the child, while a parent extends the straps 33 to the child's back and connects the one or two strap ends with the clasps 34 . The straps are then adjusted to ensure a tight but comfortable fit. On subsequent uses, the device 32 is simply held in place and the straps 33 clasped in the back. Removal simply takes place in reverse order.
[0051] The port protection device has the distinct benefits in that it:
Protects the child or user; Protects the implanted device; Promotes confidence of the user in physical activity; Is light and durable; Is easy to clean; Is simple to attach around the body/chest of the child or user and requires no special tools; Is available in universal sizes and requires no special customization to the user; Is comprised of readily available materials;
[0060] With this description it is to be understood that the Port Protection Device 32 is not to be limited to only the disclosed embodiment of product. The features of the device are intended to cover various modifications and equivalent arrangements included within the spirit and scope of the description.
[0061] While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. 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.
[0062] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these inventions belong. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present inventions, the preferred methods and materials are now described above in the foregoing paragraphs.
[0063] Other embodiments of the invention are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.
[0064] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries (e.g., definition of “plane” as a carpenter's tool would not be relevant to the use of the term “plane” when used to refer to an airplane, etc.) in dictionaries (e.g., widely used general reference dictionaries and/or relevant technical dictionaries), commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used herein in a manner more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase “as used herein shall mean” or similar language (e.g., “herein this term means,” “as defined herein,” “for the purposes of this disclosure [the term] shall mean,” etc.). References to specific examples, use of “i.e.,” use of the word “invention,” etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained herein should be considered a disclaimer or disavowal of claim scope. Accordingly, the subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any particular embodiment, feature, or combination of features shown herein. This is true even if only a single embodiment of the particular feature or combination of features is illustrated and described herein. Thus, the appended claims should be read to be given their broadest interpretation in view of the prior art and the ordinary meaning of the claim terms.
[0065] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term “approximately” should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques.
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A port protection device mainly comprised of a rigid back plate with a shock absorbing pad adhered underneath, the device being held in place against the chest of the child by using elastic straps and latching clasps. The absorbing pad provides a consistent soft contact area with the skin and chest which distributes the impact over a large area rather than localized points. This distribution reduces the possibility of pain and injury to the chest. The adjustable elastic straps allow the device be held tightly against the body and chest and not allow for movement of the device during sports and physical activity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Exemplary embodiments relate to an apparatus comprising a low-profile gutter screen that prevents leaves and other debris from entering a rain gutter. Certain exemplary embodiments relate to a rain gutter screens having a plurality of aperture water drains formed in the screen so as to permit rain water to flow into the gutter while simultaneously preventing debris from entering the gutter.
2. Background and Related Art
Many residential and commercial buildings utilize rain gutters as a means of channeling the flow of rain water. When properly functioning, rain gutters positioned on rooflines prevent erosion to both the ground and other surfaces, keep building patrons dry and also reduce the formation of ice in cold climates.
However rain gutters malfunction when filled with debris such as leaves which can be blown onto a roof. Debris can accumulate in gutters to form dams within the rain gutter or a down spout. Such dams can cause water to pool and overflow the rain gutter. In addition the pooled water can freeze, thus adding substantial weight to the gutter. This additional weight can deform attachments and supports connecting the gutter to the building thus causing the gutter's grade to be significantly changed, thus allowing even more pooling. In addition the additional stress on the drain supports can cause the supports to pull away from the building, thus allowing water to enter, freeze and cause additional damage. Similar problems occur when the water in a downspout freezes.
Preventative measures have been utilized to help reduce the formation of dams and in turn building damage. As a result rain gutter covers have been employed to reduce the accumulation of debris in the rain gutters. This is accomplished by channeling the debris across the length of the gutter and shedding the debris to the ground. Some of the water adheres to the surface of the shield through surface tension and drains into the gutter.
Problems still exist. Some shields fail to function properly in anything other than optimal conditions.
Finally, installation of some rain gutter covers requires large equipment and tools such as a hand brake or siding brake to bend the rain gutter cover to match the angle between the roof pitch and the plane created by the rain gutter's top.
BRIEF SUMMARY OF THE INVENTION
Features of an exemplary embodiment include a system for straining debris from water flowing off a roof top by providing a low-profile screen comprising a plurality of drains or apertures. The drains or apertures may be provided in a ridged surface that facilitates drainage of the water as well as automatic removal of any caught debris by wind.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates an exemplary embodiment of gutter and screen;
FIG. 2 illustrates a cross view of an exemplary embodiment of a gutter and screen;
FIG. 3 illustrates of an exemplary embodiment screen;
FIG. 4 illustrates a detailed view of an alternative exemplary embodiment of the screen in connection with a gutter;
FIG. 5 illustrates an alternative exemplary embodiment of the screen connected to a structure; and
FIG. 6 illustrates a top view of an alternative exemplary embodiment showing debris resting on a screen.
DETAILED DESCRIPTION OF THE INVENTION
A description of embodiments of the present invention will now be given with reference to the Figures. It is expected that the present invention may take many other forms and shapes, hence the following disclosure is intended to be illustrative and not limiting, and the scope of the invention should be determined by reference to the appended claims.
The term low-profile comprises a gutter screen which fits on top of a gutter where the screen lies generally between the front and back of the gutter and below the front lip of a gutter. The screen portion of the low profile screen is generally not visible unless a viewer is looking down into the gutter.
The term gutter is defined as a rain gutter affixed at the bottom edge of a roof and that catches rain water run-off.
Pitch is defined as the angle of the screen in relation to the ground.
The term “hand adjustable” or “hand manipulable” means the angle at which the shield may be bent or may be manipulated or adjusted by hand so as to conform to the angle formed by the pitch of the roof and the plane created by the top of the rain gutter.
The term snap comprises the screen being inserted between the two structures, including the building and the front of the gutter or the two outside edges of the gutter so as to place a compression force on the screen.
FIG. 1 illustrates an exemplary embodiment of a gutter screen and gutter combination. The combination includes a gutter 10 that is essentially similar to or identical to known gutters commonly used to catch and divert rain water run-off from a roof during a rain storm. As is known, rain gutters such as gutter 10 catch water and diverts it to a desired location such as a down spout or other advantageous area where the water does not fall on an underlying surface and cause unwanted erosion or other damage to a structure or the underlying surface.
In the exemplary embodiment illustrated in FIG. 1 a screen 12 lies on top of the gutter 10 between a front lip 14 and a back lip 16 of the gutter. The back lip 16 is typically positioned near the structure to which the gutter 10 is affixed, and the front lip 14 is positioned away from a structure to which the gutter 10 is affixed. FIG. 2 shows a cross-sectional view of the gutter screen and gutter combination shown in FIG. 1 , illustrating an exemplary relationship between the illustrated embodiments of the gutter 10 and the screen 12 .
FIG. 3 illustrates an exemplary embodiment of the screen 12 separated from the gutter 10 . As may be seen in FIG. 3 , the screen 12 includes a plurality of apertures 20 to allow draining of water which may flow onto the screen 12 . The screen 12 further comprises a plurality of pilot holes 22 that pierce a back mating surface 24 . The pilot holes 22 may be spaced apart in a variety of ways and may be circular to accommodate a single screw or similar fastener, as shown in FIG. 3 . Alternatively, the pilot holes 22 may be made oval in shape, with a long axis oriented along the length of the screen 12 to permit the screen 12 to slide back and forth to some extent, as desired. Permitting the screen 12 to slide laterally or side-to-side across the top of the gutter 10 , for example, might permit the user or installer to adjust the placement of the screen 12 , or similarly allow some access to the underlying gutter 10 without having to remove the entire screen 12 .
The apertures 20 may be varied in shape and size, and can be spaced to permit maximum draining of any water that may fall on the surface of the screen 12 . An objective of the aperture placement is to permit maximum draining in minimal time. Not only will quick draining of water from the surface of the screen 12 accommodate large amounts of rainfall, but it will also permit any debris which comes to rest on the screen 12 to dry quickly and blow away off the screen 12 , as will be discussed in more detail with respect to FIG. 6 .
FIGS. 2 and 4 show cross-sectional views of alternative gutter screen and gutter combinations. The primary difference between the combinations illustrated in FIGS. 2 and 4 is the use of an upwardly protruding gutter fastener 30 in the combination of FIG. 4 . The gutter fastener 30 may be any fastener or fastener system used to attach gutters such as gutter 10 to structures, including screws and screw systems. The gutter fastener 30 of FIG. 4 engages the front lip 14 as shown and extends through the back lip 16 into the underlying structure. Of important note, the gutter fastener 30 includes portions that extend somewhat above the uppermost portion of the front lip 14 of the gutter, such that placing a planar screen on the gutter 10 to rest at the level of the front lip 14 is inhibited. Instead, the screen 12 may be bent or flexed as shown in FIG. 4 to accommodate the gutter fastener 30 underneath the screen 12 without impairing the function of the screen 12 .
As shown in FIGS. 2 and 4 , the gutter 10 supports or is connected to the screen 12 at the front lip 14 and the back lip 16 . The back mating surface 24 may rest flat against a fascia board, a drip edge or other structure that is part of a structure to which the gutter 10 is affixed such as a house, or against the back lip 16 of the gutter 10 . The back mating surface 24 may be attached to the structure such as by placing screws 26 or other fasteners through the pilot holes 22 , as shown in FIG. 5 . Increasing the number of screws 26 attaching the screen 12 to the structure provides strength and support to the screen 12 and may also strengthen an attachment of the gutter 10 to the structure if the screws 26 or other fasteners pass through the gutter 10 . Essentially, the screws 26 or other fasteners act as a secondary hanging system for the gutter 10 in such installations.
In addition, the use of the screws 26 or other fasteners to attach the screen 12 at the back mounting surface 24 and independently of the installation of the gutter 10 in this way permits an installer to vary the pitch of the screen during installation of the screen 12 . Controlling the pitch of the screen 12 allows varying the installation of the screen 12 to improve function of the screen 12 according to anticipated circumstances of use of the screen 12 . For example, in situations where unusually heavy debris is anticipated (e.g. where many deciduous trees are present), the installer may decide that a slight down pitch (away from the structure) of the screen 10 would shed more debris than a perfectly level installation. Alternatively, in areas of unusually heavy water flow, the installer may decide that a slight back pitch (toward the structure) would better control water flowing off the structure's roof by acting to better interrupt or slow down the flow of water from a roof of the structure.
The exemplary gutter screen and gutter combinations illustrated by FIGS. 1 through 4 show specific potentially-advantageous features of the screen 12 . Starting from the back mating surface 24 and moving towards a front portion 40 of the screen 12 , a sloped portion 42 of the screen 12 extends from the back mating surface 24 . The sloped portion 42 is sloped so that debris will not rest near the structure, but will instead be moved toward the front portion 40 of the screen 12 . Moving any debris towards the front portion 40 allows the debris to more easily blow off the screen 12 .
In the illustrated embodiments, the sloped portion 42 has fewer apertures 20 per unit area than portions of the screen in between the sloped portion 42 and the front lip 42 . This promotes water flow over the top of the screen 12 to help flush any debris that may be resting on the sloped portion 42 towards the front of the gutter 10 , where it can more easily be blown off In certain alternative embodiments, the apertures 20 are formed with a similar frequency and size all the way to the edge of the back mating surface 24 while in other embodiments no apertures 20 are provided on the sloped portion 42 . The appropriate embodiment employed can be varied to satisfy the demands of the particular environment of installation. For example, one alternative embodiment of a screen 12 with greater number of apertures per unit area in the sloped portion 42 may be used in areas of high rainfall. The screen 12 with more apertures in the sloped are 42 may be used to increase draining. In contrast, if debris is a primary concern, a panel with fewer or no apertures 20 formed on the sloped portion 42 may be used to improve flushing the debris to the front of the gutter 10 and away from the structure during water flow.
The sloped portion 42 provides additional advantages including permitting the slope or angle of the sloped portion 42 to be adjusted to allow the effective width of the screen 12 to be modified. Modification of the effective width of the screen 12 may permit compatibility with a variety of gutter widths, and with at least some embodiments may be accomplished by hand at the site of installation. An illustration may include bending the sloped portion 210 to be closer to horizontal, thereby making the effective width of the screen 12 wider. By increasing the effective width of the screen 12 , a screen 12 primarily designed for five-inch gutters can be effectively used in connection with gutters wider than, for example, the standard five inches. Alternatively, if a gutter is narrower than the standard five inch gutter, the sloped portion 42 can be bent up or down to make the effective width of the screen 12 narrower. With certain embodiments of the screen 12 , the sloped portion 42 may be bent both up or down to reduce the effective width of the gutter cover. Also, the screen 12 may be bowed up or down along any portion of the screen 10 to permit compatibility with a variety of gutter widths. Certain embodiments provide hand adjustability in manipulating the width of the screen 12 so that any portion of the screen 12 , such as the sloped portion 42 may be adjusted by hand.
As shown in FIGS. 1-4 , certain embodiments of the screen 12 include a ridged surface 44 having a plurality of faces 46 and ridge tops 48 separated by channels 50 . The ridged surface 44 of the screen 12 allows the screen 12 to drain water regardless of the angle at which the screen 12 is installed. Thus if the screen 12 is installed with an upward pitch to help control high water flow from the structure's roof, the ridged surface 44 provide a plurality of angled surfaces to direct water flow to the channels 50 . Similarly, if the screen 12 is installed utilizing a downward pitch the plurality of angles again directs the water to the channels 50 . The same principles control water flow and draining if the screen 12 is bowed to fit a narrower gutter 10 trough, such that a portion of the screen 12 is upwardly pitched and a portion is downwardly pitched. The ridged surface 44 also allows water to drain into the holes even if the panel is installed other than perfectly level. Although the embodiments illustrated in FIGS. 1-4 illustrate certain numbers of ridge tops 48 and channels 50 , it should be understood that differing amounts of ridge tops 48 and channels 50 may be used in other embodiments.
Embodiments of the screen 12 having the ridged surface 44 provide additional advantages beyond the capture of water leaving the roof by way of interrupting the outward flow of water. For example, in certain embodiments, the apertures 20 are placed on several aspects or surfaces of the ridged surface 44 , as may be appreciated from FIGS. 1-4 . For example, in the illustrated embodiments the apertures 20 are placed on the ridge tops 48 , as well as on each of the faces 46 adjacent each ridge top 48 and in the channels 50 . The placement of apertures in these locations allows water to drain even if the channels 50 are clogged.
Additionally, the ridged surface 44 provides different planes and angles that allow debris which may fall onto the panel to be carried off by the wind. The ridged surface 44 creates varying relief which allows airflow across the surface of the screen 12 to dry and lift even heavy wet debris, the ridges forming air foils which create turbulence and spaces underneath the debris to facilitate lifting of the debris from the surface. Thus, as shown in FIG. 6 , not only does the screen 12 prevent debris 60 from entering and clogging the gutter 10 by at least trapping the debris 60 on the surface of the screen, the features of the screen 12 facilitate automatic removal of the debris 60 from the screen 12 in multiple ways, first by the action of water passing over the screen 12 , such as coming down the sloped portion 42 , second by the action of the ridged surface 44 which prevents the debris from contacting the screen on all surfaces and being trapped by a film of water around the debris 60 through the water's surface tension, and third by the action of the ridged surface 44 that allows airflow underneath the debris 60 that tends to dry the debris 60 and also to cause the debris 60 to be more easily blown away.
Furthermore, the ridge of the ridged surface 44 give the screen 12 increased structural rigidity to help support any load, such as snow, ice, or debris, which may be placed thereon. The faces 46 may aid in melting snow and ice faster because of the increased surface area exposed to sunlight.
In addition, as discussed above, the ridges of the ridged surface 44 may facilitate bending of the screen 12 slightly in order to be installed over protruding gutter hangers or other fasteners, as shown in FIG. 4 . This ability to bend or bow permits the screen 12 to be used with a variety of gutters and gutter hanging systems and both as a new system and as a retro-fit system.
Certain embodiments of the screen 12 include the front portion 40 that may incorporate an angle which promotes debris blowing off the screen 12 . In addition, the front portion 40 in some embodiments further may include apertures similar to or identical to apertures 20 to permit water that may reach the front of the screen 12 to drain off the surface of the screen 12 into the gutter 10 below. The front portion 40 in some embodiments also incorporates a small vertical section 64 that acts as a positive stop to further prevent water from flowing off the front of the screen 12 . The vertical section 64 on the front of the screen 12 may extend to approximately the height of the gutter's front lip 14 , thus the height of the vertical section 64 may depend on how recessed the screen 12 is in the trough of the 10 . In addition, the vertical section 64 may be farmed to mate with the front lip 14 of the gutter 10 so that the screen 12 can be installed by snapping the screen 12 into place. The snapping action utilizes a compression force imposed between the sloped portion 42 and the front portion 40 . The compression force secures the screen 12 in place in some embodiments and improves the efficiency of installing the screen 12 when screws or other fasteners are placed through pilot holes in the front portion 40 of the screen 12 and into the front lip 14 of the gutter. In one embodiment, pilot holes are located approximately every two inches along the front portion 40 to permit an installer to make the attachment as secure as desired or to have an attachment point anywhere deemed necessary.
Certain embodiments involve installation of the screen 12 . One exemplary method of using the screen 12 involves, working from one end of the gutter 10 or the other, an installer who takes a first section of screen 12 , tilts the back mating surface 24 into a gutter 10 and places the back mating surface 24 onto the structure's fascia hoard or drip edge. The installer may then snap the front of the screen 12 into place so that the front portion 40 is substantially flush, or may become flush against front lip 14 of the gutter 10 . If necessary to accomplish this step, the installer may bend or flex the ridged surface 44 or the sloped portion 42 or both of the screen 12 so the effective width of the screen 12 matches the width of the gutter's trough.
The installer may then attach the front portion of the screen 12 to the gutter 10 using two zip screws, one on the beginning end of the screen 12 and one in the middle. The screws might be placed in pilot holes located along the front portion 40 of the screen 12 . The installer may then attach the back mating surface 24 of the screen 12 to the structure including the structure's fascia hoard or drip edge using two zip screws, such as about a foot from either edge.
The installer may then take a second section of the screen 12 and place it on the gutter 10 so that one edge of the second section of screen 12 overlaps the ending edge of the first section of screen 12 until the last pilot hole of the first panel is aligned with the first pilot hole of the second. The second section of screen 12 is snapped into place in a similar fashion to that discussed above and a zip screw is then inserted into the aligned pilot holes to secure both panels through this hole. This process is repeated using two screws to attach each of the front and the hack of the sections of screen 12 into the gutter 10 front lip 14 and the fascia board/drip edge and overlapping the sections of screen 12 by at least the first pilot hole on the seams in front.
When the installer reaches a corner, a miter panel may be placed to fit inside and outside comers leaving a length of miter to overlap each section of the screen 12 to improve the strength of the conjunction between the screen and the miter.
Embodiments of the invention may be manufactured of any material having suitable characteristics to perform the functions discussed herein. For example, the screen 10 may be formed of materials similar to those used for existing gutters, including aluminum, vinyl and the like. As may be seen from the Figures, each section of the screen 12 may be formed from a sheet of material that is bent, thermoformed, or otherwise formed into the desired profile, such as the cross section shown in FIG. 2 . The apertures 20 and/or pilot holes 22 may be formed in the sheet of material either before or after the sheet is bent, thermoformed, or otherwise formed into the desired profile.
As may be appreciated from the above discussion and the accompanying figures, the appearance from below of a gutter screen and gutter combination may be essentially identical to the appearance of a standard gutter without a screen from below. Only upon viewing from above would the screen 12 normally become visible. As such, the screen 12 is low profile, and may be formed of or coated in a material that may differ in appearance from that of the gutter 10 . For example, the screen 12 may be formed of or coated with a dark color material such that it better absorbs the sun's light to improve melting of ice and/or snow as well as drying of wet debris 60 , even if the gutter 10 is made of or coated with a light-colored material.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as 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.
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A low-profile screen which allows water to pass through apertures formed therein to allow water to drain through the screen. A plurality of ridges are formed on the surface of the screen to allow water to drain at a number of different elevations, to increase the structural rigidity of the screen, to improve snow-melting, and to improve the screens reliance when compressive forces are exerted on the screen. Under compression the screen snaps into place. The ridges further promote debris being blown off of the surface of the screen.
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STATEMENT OF RELATED CASES
This case claims priority of U.S. Pat. Application 61/868,665, which was filed on Aug. 22, 2013 and is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to microscopy in general, and, more particularly, to in-vivo microscopic imaging of the brain.
BACKGROUND OF THE INVENTION
Related interactions often occur at different regions of the brain and/or at different depths therein. The interrelationship of these interactions contains information that can provide insight into overall brain function, health, information processing, and the effects of pharmacological agents on the brain or other parts of the body. For example, in neuroscience, it is desirable to characterize the manner in which brain activity flows from one region to the next with cellular resolution. This is essential as information processing in the brain requires the collaborative and simultaneous work of multiple brain areas. In medicine, it is desirable to follow the simultaneous effect of new drugs on multiple parts of the body. Any pharmacological agent will have multiple and simultaneous effect on various parts of the body that need to be understood to fully appreciate its mode of action.
Consequently, in brain-imaging applications, it is often desirable to image disparate regions of the brain. Conventional microscopes are often employed for this service. A conventional microscope typically includes an imaging system that is upright and includes a large vertical objective, while offering three translational degrees of freedom for the relative positioning of the microscope and a sample.
Unfortunately, conventional microscopes are ill-suited for many brain imaging applications. First, the sample is normally constrained to lie flat on the microscope stage, while a brain is a three-dimensional object.
Second, the field-of-view of a conventional microscope is typically inversely proportional to the imaging resolution desired. As a result, high-resolution microscopy is normally limited to very small fields-of-view and is typically characterized by poor depth-of-field. As a result, it is difficult, if not impossible, to image different parts and/or depths of a brain at the same time. A conventional microscope, therefore, is incapable of providing information about coordinated brain activity at such scales.
Furthermore, using multiple microscopes to simultaneously image different regions of a brain is impractical due to the considerable bulk of a conventional microscope. This size constraint is particularly problematic when imaging small brains, such as a rodent or fly brain, as is commonly used in research.
In addition, the limited degrees-of-freedom of a typical microscope makes it illsuited for use during robotic brain surgery, which requires that an imaging system be carefully placed at any desired location and orientation with respect to a patient's brain.
As an alternative to conventional microscopes, light-based robotic therapy systems have been developed. Typically, the optical end effector is optically coupled to a light source via optical-fiber connections (e.g., through a catheter, etc.). Optically coupling the end effector and light source with an optical fiber limits the spectral bandwidth—among other light properties (e.g. polarization, pulse duration in case of ultrafast light sources)—available to the practitioner.
SUMMARY OF THE INVENTION
The present invention enables microscopic imaging at any point on a three-dimensional sample along an arbitrary direction. In some embodiments, the present invention enables simultaneous microscopic imaging at multiple locations and orientations.
An illustrative embodiment of the invention comprises a robotic two-photon microscopy imaging system. The robotic imaging system integrates an optical microscopy system with a robotic system having at least one robotic arm. The inventors recognized that if the optics of the microscopy system could be appropriately integrated in and adapted for use with a robotic system, the many translational and rotational degrees of freedom of the robotic system could provide an imaging system with essentially unfettered and unprecedented access to a three-dimensional sample.
As a consequence, embodiments of the present invention are particularly well suited for in-vivo brain imaging and simultaneous multi-area imaging of disparate brain subsystems. Furthermore, embodiments of the present invention can cooperatively interact with devices implanted in the brain, thus enabling simultaneous surface-image and deep-imaging of the brain. In some embodiments, embodiments of the present invention enable control of biological samples via optogenetic techniques (i.e., using light to control neurons that have been genetically sensitized to light).
In some embodiments, the robotic imaging system comprises a robotic system having two, three or more robotic arms, enabling simultaneous imaging at multiple sites of a sample.
The optics of the robotic imaging system deliver excitation light, through the robotic imaging arms, to an optical end effector that is disposed at the tip of each such arm. A free-space optical arrangement is used to deliver the excitation light to the objective (optical end effector). The elements of the free-space optical system are integrated within the body of each robotic arm. In the illustrative embodiment, the excitation light is laser light. In some embodiments, the optical system provides multiple light beams, each having different wavelengths (and/or other properties, such as polarization, spatial mode profile, etc.), to one or more regions of a sample to be imaged. The robotic imaging system is suitable for both single-photon and two-photon excitation microscopy.
A very important aspect of the illustrative embodiment is the miniaturization of the optical end effector of the imaging system. The inventors recognized that miniaturization of the optical end effector (i.e., the objective) would enable the robotic imaging system to make full and best use of (1) multiple robotic imaging arms and (2) the two rotational degrees of freedom possessed by the robotic arms. The miniaturized optical end effector used in some embodiments of the present invention has a final cross-sectional diameter of about 1 millimeter, which enables simultaneous placement of multiple robotic imaging arms around a single animal without collision.
By way of comparison, even sophisticated prior-art devices for multi-photon imaging that include one rotational degree-of-freedom (and three translational degrees-of-freedom), such as the “Bergamo II” by Thorlabs, Inc. or the “MOM” by Sutter Instrument, incorporate a commercially available microscope objective, such as the Olympus XLUMPLFLN. Microscope objectives, such the XLUMPLFLN or others suitable for this application, have a cross-sectional diameter of about 1 inch. In the context of brain investigation, where the typical subject is a mouse brain or brain of other small animals (e.g., small primates, etc.), 1 inch represents a significant bulk. An objective of this size would not permit the simultaneous investigation of multiple brain areas in a single animal because the multiple relatively large objectives would collide. Consistent with this, to the inventors' knowledge, no provider of such imaging microscopes claim an ability for simultaneous multiple-site imaging.
With respect to two-photon microscopy, the ability to deliver laser light through free space, as in embodiments of the invention, has an extremely important advantage relative to conventional microscopy. Given the current state of optical fiber technology, the use of an optical fiber to deliver the laser light to the optical end effector would limit a biologist, for example, to working with a specific wavelength and hence a specific biological marker. But there are no such limits using free space optics; the microscope can therefore be a wide-bandwidth device (i.e., many laser wavelengths can be used). This enables the biologist to access the wide variety of biological fluorescent markers responding at different wavelengths.
Since the excitation light is not delivered to the optical end effector by a fiber but rather by an arrangement of free-space optics disposed within the robotic arms, there is the challenge of ensuring that the optical axis of light passing through each arm remains co-aligned with the “skeleton” of the arm.
Furthermore, embodiments of the invention provide an optical end effector design that is compatible with robotic motion. Robotic designs used in the illustrative embodiments employ kinematics known as “remote center of motion” (“RCM”), wherein the end effector pivots about a remote point (i.e., a point that is distanced from the mechanical bulk of the robotic arm). The robotic arms are designed this way because RCM will facilitate access of multiple optical end effectors to small samples.
Since the robot kinematics define a unique point in space (the RCM), the optical system must be compatible with an RCM robotic arm. In embodiments of the invention, the axis of the excitation light coincides with the end of the final lens in the optical end effector. This ensures that the robot will pivot about the end tip of the microscope. The design of the cylindrical lenses at the tip of the optical end effector take into account the need to coincide the remote center of motion of the robot kinematics with the end vertex of the cylindrical lens.
In the illustrative embodiment, the overall body of the robot has been “biased” to a slant of 45 degrees. As a consequence, the bulk of the robotic system that is directly above the sample is reduced. This reduces the potential for collision with other robotic arms of the imaging system. But, as previously indicated, excitation light must remain coaxially aligned with the robotic arm, including at the optical end effector without regard to robotic motion. This is achieved via the use of a special prism known as a “half-pentaprism”. Furthermore, the half pentaprism reduces the bulk of the robotic arm; its presence enables one elbow to be omitted from the robotic arm while maintaining the same maneuvering ability. As previously discussed, all elements of the optical end effector are “miniaturized” to take best advantage of the robotic arms.
An additional consideration in two-photon laser-scanning microscopy is a need to control the polarization state of the laser light that is delivered to the sample. This presents a potential problem in the context of embodiments of the present invention, wherein the joints consist of mirror pairs in periscope configuration. Specifically, when linearly polarized light reflects off of any real (i.e., commonly available) mirrors at an arbitrary angle, the reflected light does not necessarily remain linearly polarized. In fact, since the orientation of the mirrors change as the robotic arm assumes different configurations, the excitation light that exits the optical end effector should be considered to be arbitrarily polarized.
In some embodiments of the invention, the polarization problem is overcome through the use of specialized mirror coatings that ensure that linear polarization is maintained in reflection. In some embodiments, such linear polarization-maintaining mirrors are used throughout the free-space optics system within the robotic arms (with a single compensatory element to control the axis of polarization in the output light) to control the polarization state of the laser light, regardless of changes in the robot configuration. Linear polarization of light and its orientation relative to an internal robot frame-of-reference or an external laboratory frame-of-reference is maintained as the system orientation changes due to robot manipulation.
Some embodiments of the invention provide a robotic imaging system comprising a robotic imaging arm, wherein the robotic imaging arm includes (a) a first robotic arm having two rotational degrees of freedom and (b) a first free-space optical subsystem disposed in the first robotic arm, wherein the first free-space optical subsystem is configured to convey a first light signal through the first robotic arm to a first optical end effector at a distal end thereof, and wherein elements of the first free-space optical system maintain polarization of the first light signal while being conveyed through the first robotic arm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a portion of a robotic imaging system in accordance with an illustrative embodiment of the present invention.
FIG. 2 depicts a representative robotic imaging arm in accordance with the illustrative embodiment of the present invention.
FIG. 3 depicts a schematic drawing of a free-space optical subsystem that is disposed in the robotic imaging arm of FIG. 2 .
FIG. 4 depicts a schematic drawing of an objective of the optical subsystem of FIG. 3 .
FIG. 5 depicts a ray trace of the propagation of light through a half pentaprism of the objective of FIG. 4 .
FIGS. 6A-C demonstrate co-alignment of the robotic axis, the optical axis, and lens tip, for a robotic imaging arm at three different tip positions.
FIG. 7 depicts a ray trace, through the objective, for light from a sample.
DETAILED DESCRIPTION
FIG. 1 depicts a schematic drawing of a portion of an imaging system in accordance with an illustrative embodiment of the present invention. Robotic microscopy imaging system (hereinafter simply “imaging system”) 100 is a laser-scanning microscopy system that comprises imaging robots 104 - i , i=1, N (collectively “imaging robots 104 ”) and light source 110 . The number, N, of imaging robots 104 included in system 100 can be any practical number greater than one. In some other embodiments, the imaging system comprises a single imaging robot. Imaging system 100 can be used for conducting single-photon, two-photon, or, more generally, multi-photon microscopy.
Each of imaging robots 104 includes base 106 and robotic imaging arm 108 . In some embodiments, imaging robots 104 are arranged in a fixed arrangement about sample 102 .
Base 106 is a mechanically stable, fixed-position support for robotic imaging arm 108 . Base 106 also includes optical elements for receiving free-space light from light source 110 and conveying the free-space light to robotic imaging arm 108 . In some embodiments, base 106 is movable.
In some embodiments, base 106 includes telescoping linkages that provide it with positioning capability that enables reconfiguration of the arrangement of robots 104 around sample 102 . This system configurability can reduce the likelihood of collision between multiple robots during their interaction with the sample. In some embodiments, base 106 is characterized by three translational degrees-of-freedom.
Robotic imaging arm 108 comprises a microscope system integrated with robot arm such that the objective of the microscope system can be positioned and oriented anywhere within a three-dimensional volume about sample 102 . Robotic imaging arms 108 collectively enable simultaneous high-resolution imaging of different regions of sample 102 . A representative imaging arm is described below and with respect to FIGS. 2-7 .
Light source 110 is a conventional laser source operative for providing light signal 112 to each of imaging robots 104 . An exemplary light source 110 is a Ti:Sapphire laser whose center wavelength is tunable within the range of approximately 700 nm to approximately 1000 nm. It will be clear to one skilled in the art, after reading this Specification, how to specify, make, and use systems comprising a different light source.
Light source 110 is optically coupled with each base 106 via a fixed free-space optical distribution system, which affords some key advantages, particularly for two-photon imaging embodiments. Specifically, it enables the excitation light delivered to sample 102 to have an arbitrarily wide spectral width. Because different biological fluorescent markers respond to different excitation wavelengths, using a free-space optical system to convey excitation light signal 112 to sample 102 enables the use of a broad pallet of biological fluorescent markers. In contrast, currently available optical fibers would limit system 100 to as few as one excitation wavelength and, therefore, one specific biomarker.
In some embodiments, light source 110 is optically coupled with each base 106 via optical fiber. While such an arrangement potentially provides system 100 with improved flexibility in position the robot bases about sample 102 (and, hence, higher potential packing density of microscopes in the sample region), the spectral bandwidth of an optical fiber-based distribution system can limit the types of fluorophores used—particularly for two-photon laser scanning microscopy. This limitation arises due to dispersion in a conventional optical fiber, which can cause femtosecond laser pulses to broaden in time. This can result in a significant reduction of the two-photon effect. In some embodiments, light source 110 and base 106 are optically coupled via optical fibers designed for conveying ultrashort pulses. But such fibers normally have a spectral bandwidth of only a few nanometers. As a consequence, such systems are typically limited to one fluorophore.
In some embodiments, base 106 and source 110 are dimensioned and arranged to enable changing the optical fiber used to couple them, which enables the use of a different wavelength of light.
In fiber-coupled systems, light source 110 will preferably include dispersion compensation elements and one or more fiber splitters, so that each imaging robot 104 receives a dispersion-compensated portion of light signal 112 .
FIG. 2 depicts a schematic drawing of representative robotic imaging arm 108 in accordance with the illustrative embodiment of the present invention. Imaging arm 108 comprises robotic arm 202 , optical system 204 , objective 206 , and collector 208 .
Robotic arm 202 is a conventional articulated robot arm that is suitable for inclusion of optical elements within and/or attached to its links. Robotic arm 202 has two rotational degrees-of-freedom (with three translational degrees-of-freedom provided by base 106 ), which enables objective 206 to access any point of a three-dimensional space about sample 102 along any arbitrary direction. As a result, each robotic arm 202 can position its objective (i.e., part of the “optical end effector) in a manner to avoid mechanical and optical collision between all other objectives, as well as provide independent access to any location in sample 102 along its axis.
Robotic arm 202 employs kinematics known as “remote center of motion” (“RCM”) in which its end effector (i.e., objective 206 ) pivots about a remote point; that is, away from mechanical bulk of the robotic arm. An RCM design facilitates accessing a small sample space (e.g., a mouse brain, etc.) with multiple objectives.
In some embodiments, the overall body of robotic arm 202 has been “biased” to a slant of 45°. This relocates the bulk of the robotic arm to a position that is not directly above sample 102 , thereby reducing the potential for collision with other robotic arms of imaging system 100 . Optically, this 45° biasing is enabled through use of a special prism known as a “half-pentaprism,” as discussed below and with respect to FIG. 4 . In some embodiments, the body of robotic arm 202 is biased at another angle via a prism or mirror configuration characterized by an angle other than 45°.
Optical system 204 is a free-space optical system that conveys excitation light from a suitable excitation laser source to objective 206 . Optical system 204 is integrated with robotic arm 202 such that a mirror within the rotation joints rotates the laser (beam) spots at any angle without perturbing the optical alignment of the microscope.
FIG. 3 depicts a schematic drawing of an optical system in accordance with the illustrative embodiment of the present invention. Optical system 204 comprises path segments 302 - 1 through 302 - 3 and joint systems 304 - 1 through 304 - 3 .
Each of path segments 302 - 1 through 302 - 3 (referred to collectively as path segments 302 ) is a straight line optical path that is contained within a different link of robotic arm 202 .
Each of joint systems 304 - 1 through 304 - 3 (referred to, collectively, as joint systems 304 ) comprises a pair of mirrors 306 that are arranged in a “periscope configuration,” which enables light signal 112 to be optically coupled between two path segments without significant optical misalignment—even as the relative orientation of the path segments changes with the motion of robotic arm 204 .
Path segments 302 and joint systems 304 collectively define an optical path that is co-aligned with the “skeleton” of robotic arm 202 . This imbues optical system 204 with the same multiple degrees of freedom as that of the robotic arm.
One skilled in the art will recognize that the polarization state of the laser light that is delivered to the biological sample must typically be carefully controlled in two-photon laser-scanning microscopy. When linearly polarized light reflects off of a reflective element, the light can lose its linear polarization. Furthermore, when the incidence angle of the light on the reflective element changes, the polarization of the light changes as well.
In the illustrative embodiment, the reflective elements in joint systems 304 change their relative orientation with motion of robotic arm 202 . As a result, light signal 112 can become arbitrarily polarized. In accordance with embodiments of the invention, in order to provide polarization control, each of mirrors 306 comprises a coating that preserves the linear polarization of light signal 112 as it propagates through optical system 204 . In some embodiments, a compensatory element is also included to control the axis of polarization in the output excitation light.
Objective 206 , also referred to herein as an “optical end effector,” is a microscope objective suitable for illuminating an area of sample 102 with excitation light and for collecting light stimulated from the area. Objective 206 is characterized by an optical axis that is common to both the excitation light and the stimulated light. In addition, an importantly, objective 206 is miniaturized such that multiple objectives can be densely packed about sample 102 . Sufficiently miniaturizing objective 206 enables simultaneous imaging of multiple regions of sample 102 , which is precluded for prior art microscopes due to their bulk.
Miniaturization of objective 206 affords further advantages over prior-art brain imaging systems, such as fMRI. In particular, few if any of these prior-art techniques enable access to the complete brain at cellular resolution or over regions of more than a few cells at a time. In contrast, embodiments of the present invention enable recordation of hundreds of cells per imaged area, with imaged areas distributed over the brain.
FIG. 4 depicts a schematic drawing of an objective in accordance with the illustrative embodiment of the present invention. Objective 206 comprises lens 402 , dichroic cube 407 , lens 403 , half pentaprism 404 , and lens 410 .
Lens 402 is a doublet lens whose design incorporates lens tip 408 , which coincides with the remote center of motion of robotic arm 202 . In other words, lens tip 408 remains aligned with the robotic axis 406 , enabling robotic arm 202 to pivot about lens tip 408 . In some embodiments, lens 402 is a doublet having a sample-side numerical aperture of approximately 0.50.
FIG. 5 depicts a ray tracing through half pentaprism 404 . Referring to now to FIG. 5 and with continuing reference to FIG. 4 , half pentaprism 404 is an optical element comprising surfaces 502 and 504 , which collectively enable co-alignment of robot axis 406 and lens tip 408 . Half pentaprism 404 redirects light signal 112 by 45°, such that robot axis 406 coincides with the sample-side tip of lens 402 (i.e., lens tip 408 ). In some embodiments, half pentaprism comprises high-index glass that has a refractive index of approximately 1.6. In some other embodiments, half pentaprism 404 comprises a different high-index glass.
Surface 502 enables light signal 112 to initially pass through by virtue of the incidence angle of the incoming light. Surface 504 reflects light signal 112 such that it is incident a second time on surface 502 . However, this second incidence is at an angle that satisfies the total internal reflection condition for the type of glass used for pentaprism 404 . As a result, surface 504 reflects substantially all of light signal 112 to mirror 506 .
Mirror 506 comprises a dichroic mirror coating that is substantially completely reflective for the wavelengths of light signal 112 , but substantially transparent for the fluorescence wavelengths of the fluorophores used to analyze sample 102 . Mirror 506 reflects light signal 112 at an angle suitable to align it with the optical axis of lens 402 . In some embodiments, half pentaprism has a field-of-view of approximately ±10° and is substantially diffraction limited over this field-of-view.
Lens 410 is a conventional graded-index (GRIN) fiber lens. In some embodiments, lens 410 is a cylindrical lens other than a GRIN lens.
By comparing FIG. 2 (half pentaprism not included) to FIG. 3 (half pentaprism included), those skilled in the art will appreciate that the presence of half pentaprism 404 enables the final elbow of the robotic arm ( FIG. 2 ) to be omitted. (Three “elbows” [ 304 - 1 , 304 - 2 , and 304 - 3 ] are present in FIG. 3 while four elbows appear in FIG. 2 .) This permits a significant reduction in the bulk of the robotic imaging system in the vicinity of a sample (without moving this bulk directly above the sample), thereby reducing the likelihood that multiple robotic imaging arms would collide with one another and the sample under investigation when used to simultaneously image multiple regions of a sample.
FIGS. 6A-C demonstrate the co-alignments of robotic axis 406 , the optical axis of optical system 204 , and lens tip 408 , for robotic imaging arm 108 at three different tip positions. By enabling these co-alignments, the probability of inter-robot collisions and collisions with sample 102 during movement and static positioning is reduced. In these Figures, the robotic imaging arm does not include a half pentaprism, so an extra elbow is present (as previously discussed). Co-alignment of robotic axis 406 , the optical axis of optical system 204 , and lens tip 408 is also achieved, in accordance with the present teachings, when the robotic imaging arm includes the half pentaprism.
FIG. 7 depicts a ray trace for light from sample 102 as it is collected by the optical end effector. Fluorophores located at sample 102 provide light signal 702 , which includes fluorescent light at wavelengths dictated by the specific types of fluorophores used. In typical 2-photon imaging, the fluorescent wavelengths emitted by the fluorophores are shorter than those of light signal 112 .
Light signal 702 is collected by lens 402 , which then provides the light signal to lens 410 through dichroic mirror 506 . Lens 410 then couples light signal 702 into collector 208 . In the illustrative embodiment, collector 208 is a multimode optical fiber suitable for capturing a fluorescence signal from sample 102 . In some embodiments, collector 208 is a plastic fiber to provide additional flexibility relative to a glass optical fiber. Even though propagation loss in a plastic optical fiber is somewhat higher than for that of a glass fiber, for fiber lengths of about 1 meter, greater than 95% of the captured light is transmitted through the plastic fiber. The spectral bandwidth of a typical multimode fiber is wide enough so that it does not limit collection of fluorescence signals from a large number of fluorophores.
Collector 208 conveys the fluorescent light from sample 102 to suitable photodetectors (not shown).
The size of the optical end effector—objective 206 —substantially dictates the number of robotic imaging arms that can be used to analyze of a given sample. In some embodiments, the elements of objective 206 are miniaturized to a very small size; that is, less than about 13 millimeters, preferably less than about 6 millimeters, more preferably less than about 3 millimeters, and most preferably about 1 millimeter or less in diameter, to enable the simultaneous use of many robotic imaging arms on a small sample, such as a mouse brain.
In the illustrative embodiment, the source of excitation light couples to the robotic imaging arms via free-space optics. In some alternative embodiments, the light source is coupled to the robotic arms via guided-wave optics (e.g., optical fiber, etc.).
It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims.
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A robotic imaging system has at least one robotic imaging arm that includes a free-space optics subsystem. The free-space optics is capable of conveying an excitation light signal through the robotic imaging arm to an optical end effector at the distal end thereof while maintaining coaxial alignment between the optical axis and the robotic skeleton. The free-space optics is also capable of maintaining linear polarization of the light signal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the construction of composite beams in a composite steel deck floor system.
2. Description of the Prior Art
The utilization of composite action between a concrete floor slab and the floor supporting beam is well known in the art. To achieve the composite beam action, it is required to install a shear transferring device such that a compressive bending force can be developed within the cured concrete slab. This type of design is known as a composite beam design. If there is no shear transferring device provided, the floor supporting beam must be designed to resist the total imposed load and is known as a non-composite beam design. It is well known in the art that the beam strength and stiffness are greatly increased in a composite beam design as compared to a non-composite beam design. Therefore, the composite beam design has been continuously gaining popularity in the building industry. Shear studs are commonly used in the composite beam design and are installed in the following procedures. The first step is to secure the steel decks to the supporting beams. The second step is to weld the shear studs at the valleys of the steel deck profile through the steel deck onto the top flange of the supporting beam. The third step is to place the concrete shrinkage control wire mesh at 1 inch (25.4 mm) below the finished concrete slab. The fourth step is to pour and to finish the concrete slab.
In the selection of the beam size in a composite beam design, the following two factors must be considered. First, the non-composite strength of the beam must be adequate to resist the dead weight of the floor and the construction loads. Second, upon curing of the floor slab, the composite strength of the composite beam must be adequate to resist the total imposed loads including the dead load and the design live load on the floor.
The drawbacks of the prior art composite beam design include the following items.
1. In most cases, the beam size is governed by the required non-composite beam strength during the erection period.
2. The efficiency of the shear stud is affected by the concrete rib geometry formed by the valleys of the steel deck profile. The wider the concrete rib, the higher the stud efficiency. The deeper the steel deck, the lower the stud efficiency. In some cases, only a partial composite design can be achieved due to a reduction of the stud efficiency induced by the steel deck profile or the available rib locations for stud welding.
3. The concrete shrinkage control mesh is supported by spaced apart plastic chairs. The plastic chairs can be easily knocked down during the concreting operation resulting in ineffective concrete shrinkage control due to mislocated wire mesh.
SUMMARY OF THE INVENTION
The objectives of this invention include the following items.
1. To provide a shear transferring device such that the efficiency of shear transfer is not affected by the steel deck profile.
2. To utilize the shear transferring device to strengthen the noncomposite strength of the beam such that the beam size can be reduced to effectively reduce the building height.
3. To utilize the shear transferring device to secure the concrete shrinkage control mesh without using plastic supporting chairs.
4. To utilize the shear transferring device to strengthen the inplane shear resistance to improve the seismic resistance of the floor system.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a partial floor structure showing a typical floor bay of invention.
FIG. 2 is a typical fragmentary cross-sectional view taken along line 2--2 of FIG. 1 showing the cross-section of the composite beam construction of this invention.
FIG. 3 is a typical fragmentary cross-sectional view taken along line 3--3 of FIG. 1 showing the cross-section of the steel deck floor supported on the composite beam of this invention.
FIG. 4 is a typical fragmentary cross-sectional view taken along line 4--4 of FIG. 1 showing the cross-section of the composite beam of this in a girder position.
FIG. 5 is an isometric view of a typical T-beam fragment used as the shear transferring device of the composite beam construction of this invention.
FIG. 6 is a typical optimized beam profile useful in the composite beam construction of this invention.
FIG. 7 is another typical optimized beam profile having a strengthened bottom flange useful in the composite beam construction of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a plan view of a typical bay of a floor system incorporating the composite beam design of this invention. The composite steel deck slab 10 spans between composite beams 11 of this invention. The composite beams 11 span between building columns 13 or composite girders 12 of this invention.
FIG. 2 shows a typical cross-section of the composite beam of this invention taken along line 2--2 of FIG. 1. The composite concrete slab 10 comprises steel decks 14 and an overlaying concrete layer 15. The steel decks 14 are supported on the top flange of the supporting beam 16. A continuous piece of T-beam 17 is structurally connected to the supporting beam 16 by welds 18 penetrating through the bottom flange 19 of the steel deck 14. The concrete shrinkage control mesh 20 is secured at the top flange 21 of the T-beam 17. Upon curing of the overlaying concrete 15, the supporting beam 16, the T-beam 17, and the overlaying concrete 15 will act together in a composite fashion to establish the composite beam of this invention. Many advantages ar achieved by this invention as compared to the studded composite beam design of the prior art as itemized below.
1. In a studded composite beam design, the studs do not contribute any beam strength before the curing of concrete. Thus, the supporting beam 16 must be sized to resist the weight of the steel deck 14, the weight of the concrete 15, and the imposed construction load during the concreting operation. In the buildup composite beam design of this invention, the supporting beam 16 is required only to resist the weight of the steel deck without the weight of concrete while the combined strength of the supporting beam 16 and the T-beam 17 is available to resist the total load during erection. Therefore, the combined size of the supporting beam 16 and the T-beam 17 is equivalent to a single supporting beam of the studded composite beam design. It becomes apparent that a saving in the ceiling height equaling the height of the T-beam 17 is achieved by this invention, since the entire T-beam 17 is buried within the depth of the floor slab. For a highrise building, the saving in the ceiling height of each floor will result in a significant reduction of building height. Segments of the T-beams 17 can be strategically located at the regions of high bending moment rather than covering the entire length of the supporting beam 16.
2. In a studded composite beam design, the resistance against slab buckling relies on the enlarged stud head to hold down the concrete slab. In the buildup composite beam design of this invention, the floor slab is continuously locked under the long extended top flange 21 of the T-beam 17. Therefore, significant improvement in the hold down capability is achieved allowing the development of high strain in the concrete slab without composite failure. The common problem of longitudinal concrete cracks on top of a studded composite beam is eliminated by this invention.
3. The top flange 21 of T-beam 17 serves to automatically position the wire mesh 20 without the use of mesh supporting plastic chairs.
4. In the buildup composite beam design of this invention, the upward movement of the slab is restrained by the top flange of the T-beam 17 and the lateral movement of the slab is restrained by the vertical leg of the T-beam 17. Therefore, the in-plane shear resistance, which is a direct measurement of the seismic resistance is greatly improved by this invention. Other structural shapes, such as an angle or a channel, can be used in place of T-beam 17.
FIG. 3 shows a typical cross-section of the composite beam of this invention taken along line 3--3 of FIG. 1. The wire mesh 20 is positively secured to the top flange of the T-beam 17 by spaced apart tack welds 22 . The wire mesh 20 can be stretched between the T-beams 17 before applying the tack welds 22. In this manner, the proper wire mesh location is ensured during the concreting operation without the labor of placing the mesh supporting chairs. The T-beam 17 is notched as shown by the dashed line 23 to prevent interference with the profile of the steel deck 14. The bottom end of the T-beam 17 is structurally connected to the top flange of the supporting beam 16 by the welds 18 penetrating through the bottom flange of the steel deck 14. Even though the bottom of the T-beam 17 is connected to the supporting beam 16 in a spaced apart fashion at the valleys of the steel deck 14, these connections are integral parts of the T-beam 17. Therefore, the longitudinal shear transferring capacity is limited only by the strength of the welds 18 and is not affected by the geometry of the deck profile. The stud efficiency problem of a studded composite beam design is eliminated by this invention.
FIG. 4 shows a typical cross-section of the composite beam design of this invention in a girder application taken along line 4--4 of FIG. 1. In a girder application, the corrugations of the steel deck 14 are parallel to the longitudinal direction of the girder. Therefore, to incorporate this invention into the composite girder design, it is necessary to layout the steel deck 14 such that one of the steel deck valleys will be positioned on top of the bottom supporting girder. Similar to the previously explained composite beam design of this invention, the composite girder is formed by a T-beam 17 being connected to the bottom supporting girder 24 using welds 18 and an overlaying concrete slab 15 above the steel deck 14. The wire mesh 20 is supported on top of the T-beam 17. In the girder application, the T-beam 17 need not be notched.
FIG. 5 is an isometric view of a segment of the T-beam 17 useful in this invention. Notches 25 on the vertical leg 26 of the T-beam 17 are provided to prevent interference with the steel deck profile.
FIG. 6 shows a typical supporting beam profile 27 which is optimal for use in this invention. The optimal supporting beam profile 27 consists of a top flange 28, a web 29, and a bottom flange 30. The construction loading history of the buildup composite beam of this invention includes the following two stages. The first stage loading is during the erection of the steel decks and is resisted by the supporting beam. The second stage loading is during the concreting operation and is resisted by the combined action of the T-beam and the supporting beam. The second stage loading is much larger than the first stage loading and is mainly resisted by the bending strength provided by the top flange of the T-beam and the bottom flange of the supporting beam with little contribution by the top flange of the supporting beam. Similarly, the top flange of the supporting beam has little contribution to the bending strength of the composite section due to its proximity to the composite neutral axis. Therefore, the optimal profile of the supporting beam will have a thinner and narrower top flange as compared to the bottom flange. A thinner top flange will also facilitate the use of selfdrilling self-tapping screws for fastening the steel deck to the top flange of the supporting beam.
FIG. 7 shows another typical optimal supporting beam profile 31 useful for the buildup composite beam design of this invention. This optimal beam profile 31 consist of a regular symmetrical wide flanged beam 32 with thinner flanges and a stiffening steel plate 33 being structurally connected to the bottom flange of the beam 32 by welds 34.
While I have illustrated and described several embodiments on my invention, it will be understood that these are by way of illustration only and that various changes and modifications may be contemplated in my invention and within the scope of the following claims.
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This invention relates to the construction of a composite beam structure in a composite steel deck floor system. A T-shaped beam is welded through the valleys of the steel deck onto the top flange of the supporting beam. After concrete pouring, the T-beam is buried within the concrete slab to act as the shear transferring device to achieve the composite beam action. The T-beam also serves to strengthen the supporting beam in resisting the load during the concreting operation and to facilitate the placement of the concrete shrinkage control wire mesh.
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BACKGROUND OF THE INVENTION
This invention relates generally to hydraulic braking circuits for automobile vehicles, which comprise a modulation device disposed between on the one hand a transmitter device such as a hydraulic master cylinder adapted to supply fluid under pressure under the control of an operating means, (which in practice is a brake pedal), and on the other hand the braking receiver such as a slave cylinder of a wheel brake, the modulation device being controlled by a pickup sensitive to the speed of rotation of the respective wheel and which comprises at least two valves, namely an isolation valve which when open is adapted to establish communication between the transmitter device and the braking receiver, and a pressure drop regulation valve which when open is adapted to establish communication between the braking receiver and a discharge.
A braking circuit of this kind is described in the French patent filed under No. 76 14030 and published under No. 2,350,992. As a matter of public information only, it is to be noted that U.S. Pat. No. 4,155,604 granted to Fenart on May 22, 1979, claims priority from the French Patent Application No. 76 14030.
During normal braking, that is to say braking which is sufficiently moderate for there to be no risk of the locking of a wheel, the isolating valve is open and the pressure drop regulation valve closed; there is direct communication through the isolating valve between the transmitter device and the braking receiver.
When in the course of braking a risk of locking arises, the pickup sensitive to the speed of the respective wheel comes into action and brings about on the one hand the closing of the isolating valve, thereby immediately interrupting all direct communication between the transmitter device and the braking receiver, and on the other hand the opening of the pressure drop regulation valve, thereby connecting the braking receiver in a regulated manner to the discharge.
When the risk of the locking of a wheel is eliminated on the discharge of the braking receiver in this manner, the pickup sensitive to the speed of the wheel ceases to act, thereby on the one hand bringing about the closing of the pressure drop regulation valve and on the other hand opening a third valve known as the pressure rise regulation valve, which was closed during the preceding phase and which, once opened, (and as long as the driver of the vehicle maintains his action on the brake pedal) brings about a regulated rise of pressure in the braking receiver, the isolating valve remaining at least temporarily closed.
If critical conditions liable to lead to the locking of a wheel should then occur again, the modulation device will once more intervene in accordance with a pressure drop and pressure rise cycle of the type briefly analysed above.
In practice, and where the drive of the vehicle continues to operate the brake pedal, a succession of such cycles will occur.
Each cycle corresponds to a variation of the pressure in the entire brake circuit, and particularly between the braking receiver and the transmitter device.
When this transmitter device is a proportioner, that is to say an assembly composed of a high pressure accumulator and a pump feeding the accumulator, the downstream pressure being modulated under the control of the brake pedal, as described more particularly in the previously mentioned French patent, such a variation of pressure does not give rise to any major mechanical inconvenience; however, when it is transmitted to the brake pedal it may constitute a nuisance to the driver of the vehicle.
When the transmitter device is a master cylinder, this nuisance is accentuated.
Furthermore, this master cylinder receives directly the variation of pressure due to the cycle of intervention of the modulation device, to the detriment of its working life.
The main object of the present invention is to reduce or eliminate these disadvantages.
SUMMARY
The invention proposes to isolate the transmitter device from the modulation device during intervention of the modulation device and to replace the transmitter device, for the supply of fluid under pressure to the braking receiver, by a high pressure accumulator with which is associated a pump adapted to place it under load.
It is true that French Pat. No. 1,561,760 proposes to replace a master cylinder by a high pressure accumulator served by a pump, in order to prevent the master cylinder from progressively emptying into the braking receiver when the brakes are applied.
However, unlike the brake circuit according to the invention, no particular arrangement is made for isolating the transmitter device from the modulation device, which is moreover of the slide valve type and not of the clack valve type.
More precisely, the object of the present invention is to provide a hydraulic brake circuit for an automobile vehicle, of the kind comprising, disposed between a transmitter device and the braking receiver of a wheel brake, a modulation device which is controlled by a pickup sensitive to the speed of rotation of the respective wheel and which comprises at least two valves, namely an isolation valve which when open is adapted to establish communication between the transmitter device and the braking receiver, and a pressure drop regulation valve which when open is adapted to establish communication between the braking receiver and a discharge, in cooperation with a high pressure accumulator adapted to replace the transmitter device for supplying the braking receiver and with a pump adapted to place the said pressure accumulator under load, this brake circuit being characterised in that between the modulation device and the transmitter device a non-return valve is disposed which is adapted to isolate the transmitter device from the modulation device in the direction of fluid flow from the modulation device to the transmitter device.
The variations of pressure originating from the modulation device during its intervention thus have no effect on the transmitter device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a hydraulic brake circuit according to the invention;
FIG. 2 is a view similar to FIG. 1 showing an alternative embodiment; and
FIG. 3 is a further block diagram showing more specifically the environment of the brake circuits of FIGS. 1 and 2 in a motor vehicle braking circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings can be seen a hydraulic brake circuit of the kind similar to that described in French Pat. No. 76 14030 mentioned above; between a master cylinder or transmitter device 10 controlled by an operating means at the disposal of the user, which in practice is a brake pedal 11, and the braking receiver 12 of a wheel brake on the other hand, is interposed a pressure modulation device 13.
In practice, as in the example illustrated, the transmitter device 10 is a master cylinder and will be so referred to hereinbelow. The receiver 12 is usually a slave cylinder.
The modulation device 13 will be only briefly described here: it comprises a first chamber 14 connected by a pipe 15 to the master cylinder 10, and a second chamber 16 connected by a pipe 17 to the braking receiver 12; the first chamber 14 is connected to the second chamber 16 on the one hand by a first channel 19 controlled by a spring loaded valve 20, hereinafter referred to as an isolation valve, and on the other hand by a second channel 21 controlled by a valve 22, hereinafter referred to as a pressure rise regulation valve, the said second channel 21 also including a calibrated nozzle 23; the second chamber 16 is in communication with the discharge side 25 of the system via, in succession, a third channel 26 which contains a calibrated nozzle 27 and a valve 28, hereinafter referred to as a pressure drop regulation valve, and a pipe 29; finally, the regulation valves 22 and 28 are coupled to opposite ends of a rocker 30 pivotally fastened to a plunger core 31 of a solenoid 32, the operation of which is under the control of a pickup sensitive to the speed of the wheel concerned through the braking receiver 12 as will be described in more detail hereinafter.
As is more fully described and illustrated in the aforementioned French Pat. No. 2,350,992, the valve 22 includes an elongated stem 70 which has the upper end thereof connected to the rocker 30. The stem 70 carries at its lower end a frustoconical valve head 71 which is seatable on a valve seat 72 for closing flow from the first chamber 14 into the channel 21. The valve 22 is urged towards a closed position by a valve spring 73 which bears upwardly against a collar 74 carried by the valve stem 70.
The valve 20 includes a valve disk 74 which is slidably mounted on the stem 70 and is normally urged to a position closing the channel 19 by a spring 75. The valve stem 70 carries a collar 76 which is engageable with the valve disk 74 to urge it to an open position when the valve stem 70 moves downwardly.
According to the invention a non-return valve 33 adapted to isolate the master cylinder from the modulation device 13, in the direction of flow of fluid from the modulation device 13 to the master cylinder 10, is disposed between the modulation device 13 and the master cylinder 10.
A high pressure accumulator 36 is provided for replacing the master cylinder 10 in the provision of fluid under pressure to the modulation device 13 and, through the latter, to the braking receiver 12.
Through a pipe 37 this high pressure accumulator 36 is connected to the pipe 15 between the non-return valve 33 and the modulation device 13, and a pump 38 is provided for pressurizing the accumulator.
According to one aspect of the invention, this pump 38 is fitted in the discharge 25.
The general environment of the invention, as is more specifically described in French Pat. No. 2,350,992, is generally shown in FIG. 3. It will be seen that there is illustrated a conventional vehicle wheel 60 which is to be engaged with a roadway and which wheel is carried by an axle which, in turn, carries a brake rotor 61. The brake rotor 61 has associated therewith the braking receiver 12 which carries the usual pads for clampingly engaging the rotor 61 to effect a resistance to the rotation of the wheel 60.
There is associated with the wheel 60 and the rotor 61 a conventional speed detector 62 which detects the rotational speed of the wheel 60 or the rotor 61. The speed detector 62 is coupled to a control calculating unit 63 which, in turn, is coupled to the modulating device to actuate the solenoid 32.
Inasmuch as the fluid circuitry of this figure is somewhat different from that of FIGS. 1 and 2, it is pointed out here that in the illustration of FIG. 3 the modulation device 13 is coupled to the braking receiver 12 by a fluid line 64. In a like manner, the modulation device 13 is coupled to the master cylinder 10 through a fluid line 65. There is also illustrated a reservoir 66 to which the pump 38 is coupled for pumping hydraulic fluid to the master cylinder 10. A return line 67 delivers returning fluid from the modulation device 13 to the reservoir 66.
When the footpedal 17 is moved in the direction of the arrow to actuate the master cylinder, hydraulic fluid flows to the braking receiver 12, but is controlled by the modulation device 13. In accordance with the detected speed and the signal from the control calculating unit, there is a controlled flow of the hydraulic fluid from the master cylinder through the modulation device to the braking receiver 12, thereby providing for a controlled actuation of the vehicle wheel brake.
In the example illustrated in FIG. 1 the pump itself constitutes this discharge and, in the case of a pump having a piston 39 mounted for movement in a cylinder 40 under the control of a cam 41, its cylinder capacity must be established in such a manner that during a single stroke it can absorb almost instantaneously the flow of fluid corresponding to the discharge of the braking receiver 12.
In order to accelerate its intervention the piston 39 of the pump 38 is preferably held in permanent contact with the cam 41 controlling it, this being achieved by means of a spring 42.
The pump 38 is thus able to develop a reduced pressure or suction relative to the modulation device 13, and therefore in relation to the flow of fluid which it has to absorb.
In the embodiment illustrated in FIG. 1, the cam 41 of the pump 38 is driven by an electric motor 44, controlled by the brake pedal 11, for example with the aid of the contact 45 usually operated by the pedal to illuminate the rear stop lights of the vehicle, as illustrated in broken lines in FIG. 1.
The pump 38 is thus operated each time the brakes are applied, even if this braking does not call for the intervention of the modulation device 13, thus avoiding its seizing in the intervals between such interventions.
On the pipe 29 connecting the modulation device 13 to the discharge, which in this case is the pump 38, is interposed a non-return valve 46 adapted to prevent any circulation of fluid in the discharge direction, which in practice is the direction of flow from the pump 38 to the modulation device 13, and on the pipe 47 connecting the pump 38 to the high pressure accumulator 36 there is likewise interposed a non-return valve 48 preventing circulation of fluid in the direction of flow from the high pressure accumulator 36 to the pump 38.
Finally, the master cylinder 10 is directly connected to the braking receiver 12 through a pipe 49 in which is interposed a non-return valve 50 preventing circulation of fluid directly from the master cylinder 10 to the braking receiver 12; the pipe 17 is connected between the non-return valve 50 and the braking receiver 12.
In a manner known per se the high pressure acumulator 36 is of the type comprising a piston 52 mounted sealingly for movement in a cylinder 53 against the action of a spring 54.
This spring 54 is calibrated at a value such that the pressure in the high pressure accumulator 36, as soon as the latter is under load, is higher than the pressure required to lock the wheel concerned on a road surface assumed to be providing the best possible braking conditions.
In practice the calibration of the spring 54 is such that the pressure in the high pressure accumulator is e.g. at least 150 bars.
It will first be assumed hereinbelow that the conditions are such that no risk of the locking of a wheel is likely to occur.
The solenoid 32 of the modulation device 13 is therefore not receiving current, the isolation valve 20 is in the open position, and the same is true of the pressure rise regulation valve 22, while the pressure drop regulation valve 28 is closed.
When the brakes are applied, the fluid delivered by the master cylinder 10 under the action of the pedal 11 passes through the modulation device 13 before reaching the braking receiver 12, passing in succession through the pipe 15, the first channel 19 of the modulation device 13, and the pipe 17.
When the action on the brake pedal 11 ceases, the fluid flows back directly from the braking receiver 12 to the master cylinder 10 by way of the pipe 49, the nonreturn valve 50 interposed on the latter being designed to open without delay for this direction of circulation of the fluid, without giving rise to any residual pressure on the braking receiver side, and thus to avoid abnormal wear on the brake linings.
When the brakes are thus applied under normal conditions, the pressure drop regulation valve being closed, the pump 38 works without load and the high pressure accumulator 36 is discharged.
It will now be assumed that the braking conditions are such that there is a risk of the locking of the wheels.
The speed pickup controlling the solenoid 32 causes the latter to come into action; the isolation valve 20 and the pressure rise regulation valve 22 close, while the pressure drop regulation valve 28 opens.
All communication between the master cylinder 10 and the braking receiver 12 is interrupted, and the receiver 12 is brought into communication with the discharge 25 by the way of the pipe 17, the second chamber 16 of the modulation device 13, and the third channel 26 of the latter; at least a part of the fluid present in the braking receiver 12 flows back in the direction of the discharge.
The fluid thus directed towards the discharge 25 is immediately taken by the pump 38 and delivered by the latter to the high pressure accumulator 36, which is thus progressively placed under load.
Because of the special calibration of the spring 54 of the high pressure accumulator 36, as indicated above, the pressure downstream of the non-return valve 33 is always higher than the pressure upstream of the non-return valve 33, so that the latter remains closed in all circumstances and the master cylinder 10 is thus isolated from the modulation device 13.
When the critical conditions which led to the operation of the solenoid 32 have ceased to exist, the feeding of the latter is interrupted, so that the pressure rise regulation valve 22 opens and the pressure drop regulation valve 28 closes, while the isolation valve 20 remains at least momentarily in the closed position.
Through the pipe 37, the chamber 14 of the modulation device 13, the second channel 21 of the latter, its chamber 16, and the pipe 17, the high pressure accumulator 36 then again supplies fluid under pressure to the braking receiver 12, replacing the master cylinder 10 for that purpose, the master cylinder remaining isolated from the modulation device 13 by the non-return valve 33.
If critical braking conditions occur once more, the solenoid 32 will intervene again, and the operations described above are repeated cyclically.
However, because of the non-return valve 33 the master cylinder 10 is not subjected to the corresponding variations of pressure in the pipe 37.
If in the course of any of the cycles of intervention of the modulation device 13 the action on the pedal 11 ceases, either nothing will happen because the pressure in the braking receiver is zero as the result of such an intervention, or else, this pressure not being zero, the braking receiver 12 discharges normally into the master cylinder 10 by way of the non-return valve 50.
In either of these cases, the reaction of the brake circuit of the invention is sound, the release of the brake pedal 11 quite obviously indicating that no additional braking action is desired by the driver of the vehicle, at least momentarily.
As will be observed, the rise in pressure of the braking receiver 12 is effected from a high pressure which advantageously is constant, namely the pressure defined by the calibration of the high pressure accumulator 36, irrespective of the greater or lower intensity of the action of the driver of the vehicle concerned on the brake pedal 11.
The conditions under which this rise in pressure takes place are thus improved.
Like the non-return valve 50, the non-return valve 46 is preferably designed to have no residual pressure, that is to say to open without delay when a difference in pressure occurs at its boundaries, in order that the drop in pressure in the braking receiver 12 may occur without delay when that is necessary.
The suction action developed by the pump 38 because of the action of the spring 42 is advantageously favourable in this respect.
In the alternative embodiment illustrated in FIG. 2 the discharge 25 comprises not only the pump 38 but also a low pressure accumulator 58; as an example, and as illustrated, this accumulator is connected to the pipe 29 between the non-return valve 46 and a non-return valve 46'; as an alternative it is simply connected between the modulation device 13 and the non-return valve 46.
The cylinder capacity of the pump 38 can thus advantageously be reduced, which is favourable to a reduction of its cost.
Furthermore, in this embodiment the supply connection between the master cylinder 10 and the braking receiver 12 is made by way of the second chamber 16 of the modulation device 13, the master cylinder 10 being connected to the said chamber by a pipe 17 controlled by a non-return valve 50, as previously, while the connection of the braking receiver 12 to the chamber 16 in question is made by means of a pipe 57 separate from the previously mentioned pipe.
The present invention is obviously not limited to the embodiments described and illustrated, but includes any modified embodiments and/or combinations of their various elements.
In particular, the pump 38 may be permanently driven by the engine of the vehicle or by the shaft of the wheel with which the braking receiver in question is associated.
Moreover, the field of application of the invention is not limited to cases where the transmitter device adapted to deliver fluid under pressure is a master cylinder, but obviously also extends to cases where it is a proportioner.
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The invention comprises an anti-lock braking circuit of the kind which incorporates a modulation device between the master cylinder and the slave sylinder of the respective wheel. The modulation device is controlled by a pickup sensitive to wheel locking and comprises an isolation valve which in its normally open position establishes communication between the master cylinder and the slave cylinder, and a pressure drop regulation valve which can establish communication between the slave cylinder and a discharge. When locking of a wheel is sensed by the pickup, the isolation valve is closed and the pressure drop regulation valve is opened to connect the slave cylinder to the discharge, thereby reducing the braking force applied to the respective wheel. According to the invention, the modulation device incorporates a high-pressure accumulator and a pump for pressurizing the accumulator, and a non-return valve is provided to prevent fluid flow from the modulation device to the master cylinder, whereby during intervention of the modulation device the necessary fluid pressure for the slave cylinder is provided by the accumulator and the master cylinder is isolated from the modulation device so that undesirable variations in pressure on the brake pedal are avoided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a heatable roll, in particular for processing web-like materials, such as paper.
2. Description of the Prior Art
For the processing of web-like materials, such as paper, rolls are known which can be heated from the inside. In a conventional constructional form a heated liquid heat carrier flows through passages or bores which are formed closely beneath the roll surface. The heat carrier thereby gives its thermal energy at least partially up to the bore wall and thus to the roll wall. The roll wall transfers the thermal energy to the web-like material to be processed, for example to dry it.
In this known constructional form for a heatable roll an external means is necessary for heating the heat carrier liquid and keeping it at a predetermined temperature. In many countries, for example Sweden, containers of cast iron are not allowed for closed heat carrier circuits with temperatures above 140° C. Consequently, chilled rolls cannot be heated to temperatures above the specified maximum temperature. On the other hand, high temperatures are desired in the treatment of web-like materials. It is for example perfectly usual in Germany to employ roll temperatures of 200° C. and more.
Furthermore, heatable rolls are known in which the roll jacket rotates about a stationary core. The stationary core is equipped with one or more induction coils. In operation, via the induction coils eddy currents are induced in the rotating roll jacket which heat up the latter by ohmic heat.
Such a constructional form of a heatable roll has the disadvantage that it is extremely sensitive because in a practical embodiment, for example for use in a paper calender, a roll tube has to be supported in cantilever manner over a span of over 8 m above a coil core of the same length. Shocks, which cannot be avoided in practical operation of paper machine glazing rollers, and unbalances, which as a rule occur to varying extents in heatable rolls, necessarily lead to vibrations which result in contacts between rotating and stationary parts. This leads necessarily to damage of the parts concerned. Premature wear or even total breakdown would be the result.
Finally, it should be mentioned that heatable chilled rolls having an external supply of heat carrier liquid come under further safety regulations in countries such as Sweden with regard to the volume content of heat carrier liquid. These safety regulations are intended to reduce the danger originating from the escaping heat carrier liquid on breakage of such rolls.
SUMMARY OF THE INVENTION
The invention therefore has as its object the elimination of the disadvantages of the prior art and in particular the provision of a heatable roll which has high safety and great reliability.
This object is achieved in a heatable roll, in particular for processing web-like material, for example paper, comprising a roll body having peripheral passages or bores which are formed preferably parallel to the axis of the roll body and at least one, as a rule two, preferably screwed-on journal pins, by the improvement that in the bores heating elements are arranged which extend in the axial direction parallel to the roll body.
Further expedient developments are defined by the features of the subsidiary claims.
According to the invention, into the peripheral bores in the roll body of a heatable roll rod-like heating elements are inserted which extend in the same direction as the bores, i.e. parallel to the axis of the roll body.
If these heating elements are expediently formed as electrical resistance heating elements it is possible to dispense with sealing heads on the journals, since now no heat carrier liquid is introduced into the roll or need be removed therefrom and supplied to an external heating means.
In this embodiment the necessary electrical heating energy is supplied for example via wiper contacts to one of the two journals of the heatable roll. Via a line system within the roll body the electrical current is then supplied to the electrical resistance heating elements. The transfer of the thermal energy from the resistance heating element to the roll is by convection by means of suitable convection liquid, for example water. This embodiment has the advantage that only a relatively small amount of convection liquid is required, that is only the amount which is sealingly enclosed in the usually sealed peripheral bores or passages near the roll surface.
In a further extremely expedient embodiment in the peripheral axial parallel bores tubes, as a rule steel tubes, are inserted through which the heat carrier liquid is supplied, as it were separately from the material of the chilled roll. Adequate thermal contact between the introduced tube and the material of the chilled roll can also be implemented by the filling of the intermediate space between tube and bore with a convection liquid.
This embodiment has the advantage that the aforementioned safety regulations do not apply to such rolls and consequently need not be taken into account therefor.
The volume of the convection liquid in the individual peripheral bores separate from each other is as a rule so low that in spite of the pressures to be expected no approval problems are likely to be encountered.
This embodiment consequently has the advantage that it is possible to use a heat carrier to be externally heated and nevertheless temperatures above 140° C. in countries with strict safety regulations because the heat carrier liquid in this case does not have any direct contact with the chilled cast material of the heatable roll but as a rule is guided solely in a system of steel tubes.
Due to the peripheral passages formed near the surface in which the heating elements are arranged, the heat source is close to the location where the heat requirement occurs. Temperature gradients due to long transport paths thus hardly occur. The principle of electrical resistance heating is very simple and robust so that disturbances in operation are hardly to be expected. By the filling with convection liquid the temperature of the heating elements is kept far below the usual temperatures for resistance heating elements so that the life of the heating elements is practically unlimited.
In a further advantageous embodiment the space between the heating tube and bore is filled only partially with a boilable convection liquid, for example water, and otherwise evacuated.
Since the heat exchange does not take place directly between the heating elements and the roll wall but via the convection liquid, it is ensured that the temperature distribution in the axial direction is very uniform Condensation of water vapour in such a system will take place where the temperature is lowest. Consequently, the heat supply takes place automatically exactly at the point which has the greatest heat requirement or the temperature of which has the greatest difference from other points. The amount of condensate is regulated in the same manner, i.e. the greater the temperature difference to a specific region the greater the amount of condensate will be there. In this manner an extremely balanced surface temperature of the roll is achieved although the safety and reliability are nevertheless the main aims.
Expediently, for the temperature regulation near the surface of the roll jacket at least one temperature sensor is provided. Via a conventional control circuit in this manner rapid reaction to temperature deviations can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in detail hereinafter with reference to preferred embodiments with the aid of the attached drawings, making further advantages and features of the invention apparent. In the drawings:
FIG. 1 is a longitudinal section through a preferred embodiment of the heatable roll according to the invention and
FIG. 2 is a fragment of a longitudinal section through a further preferred embodiment of a heatable roll according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a heatable roll according to the invention is denoted generally by the reference numeral 10. Said roll 10 comprises a roll body 12, at the ends of which flanges or journals 14a, 14b are attached. As a rule, such journals 14a, 14b are screwed on with bolts or the like. Via the journal 14b, which is located and guided in a roll bearing, not illustrated here, via leads 22 and via wiper contacts 24 and current pickups 25 electrical energy is introduced into the roll body 12. The journal 14a is used both for guiding in the roll bearing and for the drive for the rotational movement of the roll 10.
Peripheral axial parallel bores 16 formed near the roll surface are provided with heating means 18 which in the present case are electrical resistance heating elements 18.
At the respective ends of the heating elements 18 seals 28 are disposed which enclose the liquids used for the heating in sealing manner. As a rule the seals 28 are provided as close as possible to the respective ends of the roll body 12 in order to achieve a uniform heating effect over the entire roll body 12. In the space between the heating elements 18 and the bore wall of the bore 16 the convection liquid is disposed. It is for example water. The intermediate space between the tube 19 and the wall of the bore 16 is as a rule filled to the greater part with water.
The resistance values of the electrical resistance heating elements 18 are adapted to the necessary heating power and life considerations.
A bore 26 disposed centrally in the roll body 12 serves for the supply and carrying away of the electrical supply current.
At least one temperature sensor 20 is provided near the surface of the heatable roll 10.
In FIG. 2 a further preferred embodiment of the roll 10 according to the invention can be seen. The cutout illustrated is disposed at one end of the roll body 12.
In this embodiment a heat carrier (for example thermo-oil) is heated externally of the roll and introduced into the roll 10 via a rotating sealing head at one of the flanges 14a or 14b. Within the roll body 12 the heat carrier is conducted through tubes, as a rule steel tubes, which are mounted sealingly in the peripheral bores 16. The heated thermal carrier liquid is conducted in the tubes 18 and via the wall of the tube 18 gives its thermal energy up to a convection liquid which is disposed in the sealed intermediate space between the tube 18 and the wall of the peripheral bore 16. The convection liquid usually only partially filling this cavity is preferably water.
The tube 18 is inserted into a flange body 38 which in cooperation with a corresponding flange body 38 on the opposite side of the roll body 12 clamps the tube 18 in the bore 16 and thus holds said tube. A weld seam 30 ensures the sealing of the interior of the tube 18 with respect to the cavity between the tube 18 and the wall of the bore 16. A pressure body 36 provided with seals 42 seals the cavity between the tube 18 and the bore 16 at the end side. The pressure body 36 is applied via one or more nuts 34 with external and internal thread 10 and held in the roll body 12.
For introducing or replenishing the second heat carrier liquid (distilled water) a bore 32 may be provided which leads into the cavity between the tube 18 and the wall of the peripheral bore 16. This additional supply bore 32 must of course be sealingly closable.
Since the heat exchange does not take place directly between the heating elements 18 and the roll body 12 but via the boiling convection liquid, it is ensured that the temperature distribution in the axial direction of the roll body 12 is very uniform. Condensation of water vapour will take place in this system preferably at the point where the temperature at the roll body 12 is lower. Consequently, the heat supply to the roll body 12 takes place automatically at the point exhibiting temperature deviations. In this manner a very balanced surface temperature of the roll 10 according to the invention is achieved.
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A heatable roll, in particular for processing web-like materials, for example paper, which includes a roll body having peripheral passages or bores which are preferably arranged parallel to the axis of the roll body, and at least one, and preferably two, screwed-on flange journals. Heating elements are arranged in the bores which extend in the axial direction parallel to the roll body.
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RELATED APPLICATIONS
[0001] This application is a Divisional of Ser. No. 09/648,413, filed Aug. 25, 2000 which claims the benefit of Provisional Application No. 60/186,800, filed Mar. 3, 2000 both of which are incorporated herein by this reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Wavelength division multiplexing (WDM) systems typically comprise multiple separately modulated laser diodes at the transmitter. These laser diodes are tuned to operate at different wavelengths. When combined in an optical fiber, the WDM optical signal comprises a corresponding number of spectrally separated channels. Along the transmission link, the channels are typically collectively amplified in gain fiber, such as erbium-doped fiber and/or regular fiber, in a Raman pumping scheme. At the receiving end, the channels are usually separated from each other using thin film filter systems, to thereby enable detection by separate photodiodes.
[0003] The advantage of WDM systems is that the transmission capacity of a single fiber can be increased. Historically, only a single channel was transmitted in each optical fiber. In contrast, modern WDM systems contemplate hundreds or thousands of spectrally separated channels per fiber. This yields concomitant increases in the data rate capabilities of each fiber. Moreover, the cost per bit of data for WDM systems is typically less than comparable non-multiplexed systems. This is because any amplification system required along the link can essentially be shared by all of the separate channels transmitted in a single fiber link. With non-multiplexed systems, each channel/fiber would require its own amplification system.
[0004] Nonetheless, there are challenges associated with implementing WDM systems. First, the transmitters and receivers are substantially more complex since, in addition to the laser diodes and receivers, additional optical components are required to combine the channels into, and separate out the channels from, the WDM optical signal. Moreover, there is the danger of channel drift where the channels loose their spectral separation and overlap each other. This interferes with channel separation and demodulation at the receiving end.
SUMMARY OF THE INVENTION
[0005] In order to ensure that proper guard bands are maintained between adjacent channels and to also ensure that the carrier frequencies or wavelengths of the channels are correct both relative to other channels and relative to their wavelength assignments, optical monitoring systems are required in most WDM transmission systems. They are also useful in WDM channel routing systems, such as add/drop multiplexers and switches to ensure that the specific optical channels are being property controlled. Further, information concerning the relative and absolute powers in the optical channels is important as feedback to variable attenuators, for example.
[0006] Historically, however, optical monitoring systems have been relatively large, complex systems. Their size and complexity, and resulting maintenance requirements, prevented them from being integrated into systems offering high levels of functionality such as cross-connect switches, amplifier systems, and integrated receivers, monitoring systems and transmitters, for example.
[0007] The present invention concerns an optical monitoring system that is capable of being integrated into a small package to be used as a subsystem, or possibly even as a stand-alone system, in a WDM system, or other application requiring optical spectral monitoring.
[0008] In general, according to one aspect, the invention features an integrated optical monitoring system. It comprises a hermetic package and an optical bench sealed within the package. An optical fiber pigtail enters the package via a feed-through to connect to and terminate above the bench. A tunable filter, connected to the top of the bench, filters an optical signal transmitted by the fiber pigtail. A detector, also connected to the bench, detects the filtered signal from the tunable filter. Thus, the entire system is integrated together, on a single bench within a preferably small package. This configuration makes the system useful as a subsystem, for example, in a larger system offering higher levels of functionality and optical signal processing capability.
[0009] In the preferred embodiment, an isolator is also integrated onto the bench to prevent back reflections into the fiber pigtail.
[0010] The preferred embodiment uses a reference signal source, also preferably integrated on the optical bench that generates a reference signal, which is filtered by the tunable filter. Such a reference signal enables absolute measurements of optical signal wavelength to ensure that each optical signal is broadcasted at the proper wavelength and to detect such problems as wavelength drift across all of these signals. As a result, the system is capable of detecting absolute frequency, in addition to ensuring that guard-bands are maintained between adjacent channels, for example.
[0011] In the current embodiment, the reference signal source comprises a broadband source and an etalon. The etalon converts the broadband signal from a super luminescent LED (SLED), for example, into a signal with stable spectral characteristics.
[0012] In other embodiments, two physically discrete tunable filter cavities are utilized. Typically, the cavity tuning is synchronized to obtain net signal transmission through both cavities.
[0013] In general, according to another aspect, the invention is also characterized as a method for constructing an integrated optical monitoring system. This method comprises installing an optical bench in a hermetic package. A fiber pigtail is inserted through a fiber feed-through, into the package, and terminated on the optical bench. A tunable fiber is also installed on a top of the bench to filter an optical signal from the fiber pigtail. Finally, a detector is installed on the bench to detect the filtered optical signal from the tunable filter.
[0014] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
[0016] [0016]FIG. 1 is a schematic, block diagram illustrating a first embodiment of the optical monitoring system with insets showing the spectral characteristics of the WDM signal and filter transfer function; according to the present invention;
[0017] [0017]FIGS. 2A, 2B, and 2 C are spectral plots of exemplary WDM signals illustrating various problems that can be diagnosed with the optical channel monitoring system of the present invention;
[0018] [0018]FIG. 3 is a more detailed block diagram illustrating the optical train of a first embodiment of the optical channel monitoring system of the present invention;
[0019] [0019]FIG. 4 is a spectral plot illustrating the WDM system and reference signals of the first embodiment of the optical channel monitoring system of the present invention;
[0020] [0020]FIG. 5 is a perspective view of the integrated optical channel monitoring system of the first embodiment of the present invention;
[0021] [0021]FIG. 6 is a partial perspective view showing a hermetic package with its top removed and the optical bench installed inside the package;
[0022] [0022]FIG. 7 is a schematic diagram showing an alternative implementation of a portion of the optical train surrounding the tunable filter in which the filter is arranged in a double pass configuration;
[0023] [0023]FIG. 8 is a spectral plot of the filter's transfer function in a single and double pass configuration, according to the invention; and
[0024] [0024]FIG. 9 is an optical train of an optical power monitor without the integrated reference signal source/detector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] [0025]FIG. 1 illustrates an optical system monitoring system 100 , which has been constructed according to the principles of the present invention.
[0026] In the preferred or typical implementation, the system receives a WDM signal 14 , the spectral characteristics of which are illustrated by inset plot 10 . Specifically, plot 10 shows power as a function of wavelength. The WDM signal 14 comprises multiple channels or modulated carrier signals 12 . In the present scheme, these channels are distributed in two bands, typically termed the C-band, which stretches from 1530 to 1565 nm, and the L-band, which stretches from 1570-1605 nm.
[0027] The WDM signal 14 enters the monitoring system 100 . According to the first embodiment, a wavelength reference signal 111 from a reference source 110 is added to the WDM signal 14 . The combined WDM and wavelength reference signal 14 / 111 is then filtered by a tunable filter 150 . Inset plot 114 illustrates an exemplary filter transfer function for the tunable filter 150 . The transmission peak 116 is variable based upon a control signal 120 , which is generated by the driver electronics 118 under control of the controller 128 . The driver electronics include includes a DC-DC power supply, a ramp generator, a thermo-electric cooler drive circuit, and LED driver.
[0028] The combined optical signal 16 , which has been filtered by the tunable filter, includes both the filtered wavelength reference signal and the filtered WDM signal 14 . The filtered reference signal is then detected by a reference detector 122 , and the filtered WDM signal is detected by a signal detector system 124 . These detectors yield electronic signals that are received by post processing electronics 126 . A subsequent controller 128 performs analysis functions such as channel inventory.
[0029] In the preferred embodiment, the post processing electronics 126 includes optical receiver circuits, the signal and wavelength reference and digital hardware, including an analog to digital converter.
[0030] Preferably, each detector operates in a differential detection scheme to minimize common-mode noise with gain-switching multiplexor to increase dynamic range. Gain switching is performed with a 4:1 multiplexor and several resistors. This configuration allows for different receiver sensitivities to be obtained via software command of the processor 128 . The advantage of doing this is to allow for an increased dynamic range. Each scan is performed several times at different gains and a recorded signal is combined in software.
[0031] In the preferred embodiment, the analog to digital converter samples at 200 kilo-samples per second to one Megasamples per second. The controller 128 with the required RAM allows for the storage for samples and processing.
[0032] According to the preferred embodiment, the optical channel monitoring system of FIG. 1 has a number of different modes of operation. In a basic mode, that is a single channel scan, an increasing ramp voltage is applied to the tunable filter 150 . This drives the changes in the size of the Fabry-Perot cavity of the filter 150 in a quasi-linear fashion. Because of the self calibration, the particular characteristics of the voltage ramp are not critical, since continuous calibration is performed by the inclusion of the out of band reference signal.
[0033] [0033]FIGS. 2A, 2B, and 2 C illustrate different problems that can be characterized by the optical system monitoring system 100 . For example, in FIG. 2A, the relative strengths of the signals 12 , along with their absolute signal strengths relative to the noise floor 14 , are detectable. This information can be used as a control signal an upstream or downstream variable attenuator. As illustrated in FIG. 2B, inter-channel artifacts 16 are also detected. Finally, as illustrated in FIG. 2C, gain tilt problems, typically added by amplification systems, are also identifiable. Nonetheless, it should be understood that the present invention has applicability to many other applications where the spectral content of a signal is relevant.
[0034] [0034]FIG. 3 shows the optical train of the optical channel monitoring system.
[0035] The fiber 132 terminates above an optical bench 134 . The optical signal 14 is emitted out of the typically cleaved or cleaved-polished end-face of the fiber.
[0036] The optical signal is typically diverging as it is emitted from the fiber's core. It is collimated by a first collimation lens 136 . Preferably, all lenses are formed utilizing mass-transport processes as described in U.S. Pat. No. 5,618,474, the teachings of which are incorporated herein by this reference in their entirety. The invention, however, is compatible with other types of microlenses such as those generated by diffractive, binary optics, gradient index processes, or refractive element replication, for example.
[0037] A dichroic mirror 140 is used to add the reference signal 111 to the optical signal 14 . These dichroic mirrors or filters are typically referred to as WDM filters. In the illustrated implementation, the WDM filter 140 is reflective in a band surrounding 1300 nm, but transmissive in a band surrounding 1500 nm.
[0038] In the illustrated embodiment, the 1300 nm reference signal is generated by a light emitting diode 142 . In one implementation, the light emitting diode is a super luminescent light emitting diode (SLED).
[0039] The diverging beam from the LED is collimated by a second collimating lens 144 . An etalon 146 is used to convert the relatively wide-band signal from the SLED into a reference signal with stable spectral characteristics. More specifically, the etalon 146 functions as a Fabry-Perot filter with a 200 GigaHertz (GHz) free spectral range (FSR). This effectively converts the SLED's continuous, broadband spectrum into a signal with energy peaks every 200 GHz. These peaks are stable, particularly when the temperature of the system is controlled by a thermoelectric cooler or is otherwise stabilized.
[0040] A fold mirror 145 redirects the reference signal to the WDM filter 140 . It should be noted, however, that this mirrors is not required, but is simply used to facilitate integration of the system on a compact bench.
[0041] The combined optical signal 14 / 111 is transmitted through an isolator 138 . This component is used to prevent back-reflections from the subsequent optical components into the fiber 132 .
[0042] A first focusing lens 148 is used to focus the collimated combined beam 14 / 111 onto a tunable filter 150 . After the tunable filter, the beam is recollimated by a third collimating lens 152 , and transmitted to a second dichroic/WDM filter 154 .
[0043] The second WDM filter 154 functions to separate the filtered reference signal from the filtered optical signal in the filtered beam 16 from the tunable filter 150 . In the illustrated implementation, the second WDM filter 154 is reflective in a band around 1300 nm, but transmissive in a band around 1500 nm. As a result, the filtered reference signal is directed to the wavelength reference detector 122 for optical-electrical conversion.
[0044] The filtered optical signal is transmitted to the signal detector system 124 . In the illustrated embodiment, the L- and C-bands are separated from each other by a third WDM filter 156 . This WDM filter 156 is reflective to the C-band and transmissive to the L-band. As a result, the C-band of the WDM signal is detected by a C-band photodiode 158 ; the L-band is transmitted through the WDM filter 156 to be detected independently by an L-band photodiode 160 . In other embodiments, more that two bands, such as three or four, are detected simultaneously by adding additional WDM filters and detectors.
[0045] The FIG. 3 embodiment provides for out-of-band calibration. This yields the advantage that the calibration can occur simultaneously with wavelength monitoring. Specifically, one or more of the filter's modes are used for signal detection while another mode is used to simultaneously filter the calibration signal.
[0046] In alternative embodiments, a similar stable source is used for in-band calibration. One downside to such embodiments, however, is the fact that complex post processing and/or time multiplexing functionality is required upstream of the detectors to switch between signal monitoring and signal calibration.
[0047] In alternative embodiments, other LED sources are used, such as LED sources operating at approximately 1400 nm, such as an InGaAsP SLED.
[0048] The salient features of the tunable filter 150 are its selectable free spectral range. In the preferred embodiment, the free spectral range is 20 nm<FSR<170 nm at 1550 nm wavelength. It preferably also has high finesse, i.e., greater than 3,000, and a compact size.
[0049] In the preferred embodiment, the filter is as described in patent application Ser. No. 09/649,168, by Flanders, et al., entitled Tunable Fabry-Perot Filter, filed on an even date herewith, this application is incorporated herein by this reference.
[0050] In the preferred embodiment, a 40 nm FSR is selected. This enables simultaneous scans of the C and L-bands, in addition to calibration relative to the reference band. Generally, to enable simultaneous scanning, the FSR of the filter must be greater than the bandwidth of at least one of the bands of interest so that successive modes of the filter can access both bands simultaneously. The FSR, however, must be less than the combined bandwidth of bands, again to enable simultaneous access. Generally, the FSR is determined by the length 1 of the Fabry-Perot cavity in the filter, FSR=21/c.
[0051] This three-way simultaneous scanning reduces the total scan time while providing for simultaneous calibration. In other embodiments, the free spectral range of the tunable filter is increased to 57.5 nm to enable monitoring of the optical service channels that flank the C-and L-bands.
[0052] In some implementations, a spatial mode aperture is used in conjunction with the tunable filter. Such intra-filter apertures are desirable when extra cavity mode control devices are not used. For example, in some other implementations, a length of single mode fiber follows the filter to attenuate higher order modes.
[0053] [0053]FIG. 4 is a plot of power as a function of wavelength illustrating the spectral relationships between the active and passive optical components of FIG. 3 embodiment.
[0054] Plot 210 illustrates the spectrum of the light emitted by the SLED 142 . As illustrated, it is a relatively broadband signal stretching from approximately 1250-1350 nm. The etalon, however, functions as a Fabry-Perot filter to convert the wideband output to a series of spikes spaced at 200 GHz centered around 1300 nm.
[0055] Plot 214 illustrates the reflectance of the first WDM filter 140 . It is reflective in the 1300 nm range, but transmissive around the 1550 nm range. This allows the combination of the reference signal 111 and the optical signal 14 to produce the combined signal 14 / 111 .
[0056] Plot 220 shows an exemplary optical signal 14 , comprising multiple energy spikes associated with each channel, stretching across the C and L-bands between approximately 1500 nm to over 1600 nm. Spectrally on either side of the channels are two optical service channels 222 , 224 , which can be used to transmit additional channel information.
[0057] Plot 216 is the reflectance curve of the third WDM filter 156 . It has a sharp transition between the C and L-bands to thereby separate the two bands so that they can be separately detected by the C-band photodiode 158 and the L-band photodiode 160 .
[0058] [0058]FIG. 5 illustrates the integration of the optical channel monitoring system 100 on a single, miniature optical bench 134 . It also illustrates a second embodiment of the optical channel monitoring system, which does not have separate detectors for the C- and L-bands. Instead, a single detector 160 is used to detect the optical signal. This has the advantage of simplified construction, but negates any opportunity for simultaneous C- and L-band scanning. One implementation relies on an increased filter spectral range of about 115 nm or greater to scan the entire signal band of interest. In other implementations, the C/L band WDM filter 156 is installed in front of the detector 160 to provide for C or L band scanning only.
[0059] Specifically, the fiber 132 is terminated on the bench 134 at a mounting and alignment structure 252 . This mounting and alignment structure 252 holds the fiber in proximity to the first collimating lens 136 held on its own mounting and alignment structure 254 .
[0060] In the reference signal optical train, the SLED 142 generates the broadband beam, which is focused by the second collimating lens 144 held on mounting and alignment structure 256 . This collimates the beam to pass through the etalon 146 installed on the bench 134 . The reference beam generated by the etalon is reflected by fold mirror 145 to the first WDM filter 140 . As a result, the combined beam 14 / 111 is transmitted to the isolator 138 , which is installed directly on the bench 134 in the illustrated implementation.
[0061] After the isolator, a focusing lens 148 held on mounting and alignment structure 258 focuses the combined beam onto the tunable filter 150 , which is held on the filter mounting and alignment structure 258 . The beam from the filter 150 is re-collimated by a third collimating lens 152 held on mounting and alignment structure 260 . This beam is then separated into the reference beam and the optical signal by a second WDM filter 154 . The reference signal is detected by detector 122 . The filtered optical signal is transmitted through the second WDM filter 154 to the signal photodiode 160 .
[0062] Also shown is the installation of the thermistor 270 , which is used by the controller to control the package's thermoelectric cooler
[0063] [0063]FIG. 6 illustrates the installation of the optical bench 134 into a hermetic package 300 . The thermoelectric cooler 310 is installed under the bench 134 . The optical fiber 132 passes through an optical fiber feed through 312 to terminate on the optical bench 134 . In the figure, the hermetic package 300 has its top removed. Preferably, this is a standard 0.75×0.5 inch butterfly hermetic package.
[0064] [0064]FIG. 7 is a block diagram illustrating the configuration of the tunable filter according to a third embodiment of the present invention. In this embodiment, the tunable filter 150 in FIG. 3, for example, is replaced with the illustrated system.
[0065] Specifically, the combined optical signal/reference signal 14 / 111 from the isolator 138 is sent through a polarization scrambler 410 . This yields an unpolarized signal, of which 50% passes through polarization beam splitter 412 . The transmitted signal is indicated by reference numeral 411 . The polarization scrambler ensures that the incoming beam has a uniform distribution of polarization states so that the polarization beam splitter always passes exactly 50% of the light. Without the scrambler, the incoming beam could have had its polarization state either parallel or perpendicular to the polarization beam splitter, or an intermediate state, meaning that the transmitted beam would have varied between 0 and 100%.
[0066] The optical signal essentially passes through two, series, synchronized Fabry-Perot filter cavities 416 . This is accomplished by sending the signal to the right, in FIG. 7, through the tunable filter 150 , reflecting the signal with a Faraday mirror 414 and then sending the signal back through the Fabry-Perot cavity 416 a second time. The Faraday mirror 414 has the effect of rotating the polarization of the beam 411 by 90 degrees.
[0067] The signal with the rotated polarization is separated by the polarization beam splitter 412 and is output as signal 16 . This combined and twice-filtered signal is sent to a single detector, a detector system, or L-band, C-band, and reference signal photodetectors 122 , 158 , 160 , depending on the implementation/embodiment.
[0068] [0068]FIG. 8 illustrates in increased wavelength selectivity obtained by the double pass or two filter cavity arrangement. The transfer function a single pass filter is illustrated by plot 510 —whereas in the double-pass configuration, much steeper transfer function is achieved as illustrated by plot 512 .
[0069] The double-pass or two filter cavity configuration has the advantage of also de-emphasizing any side lobes in the filter's transfer function.
[0070] [0070]FIG. 9 shows the optical train according to still another embodiment of the present invention. This configuration is termed an optical power monitoring system. The reference signal is not present. C-band and L-band photodiodes 158 , 160 , however, are provided. This is useful when the relative spacing of the optical channels 12 is important, but not necessarily the absolute wavelengths of those optical channels 12 in the optical signal 14 .
[0071] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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An integrated optical monitoring system comprises a hermetic package and an optical bench sealed within the package. An optical fiber pigtail enters the package via a feed-through to connect to and terminate above the bench. A tunable filter is connected to the top of the bench and filters an optical signal transmitted by the fiber pigtail. A detector, also connected to the bench, detects the filtered signal from the tunable filter. Thus, the entire system is integrated together, on a single bench within a preferably small package. This configuration makes the system useful as a subsystem, for example, in a larger system offering higher levels of functionality and optical signal processing capability.
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FIELD OF THE INVENTION
The present invention relates to display devices, and more particularly, to a rapid detection method for the decay of a liquid crystal display device having an LED backlight and a display device provided with a rapid compensating device for decay.
DESCRIPTION OF THE RELATED ART
As Light emitting diodes (LEDs) are continuously improved in luminous efficacy and cost efficiency, light crystal displays that employ LEDs as backlight light sources are increasingly adopted by the market because of their slim designs and potential to reduce power consumption. With the so-called “local color dimming control” technology developed in recent years, the adoption of LEDs as a backlight source is beneficial to modulate the regional brightness of an LCD, thereby raising the contrast ratio thereof. Especially, in the case where RGB LEDs are used in an LCD, the color gamut of the LCD can be advantageously enabled to exceed the NTSC Standard and avoid moving blur.
Typically, there are two types of white light LEDs used as backlight sources, one integrating a blue light LED chip with a phosphor powder wherein electrons of the phosphor powder are excited by the blue light and then return to their ground state to emit a light having a longer wavelength which in turn combines with the blue light to create white light; the other directly combining RGB LED chips to mix the three primaries into white light. However, regardless of the types of white light LEDs, the brightness and chromaticity values will more or less vary from one LED die to another, causing non-uniformity in light emission from diverse regions of a single backlight.
For example, in the case of a white light LED integrating a blue light chip with a phosphor powder, the brightness and chromaticity of white light emitted from the LED will be affected by the factors such as the wavelength of the blue light and the composition and mixture condition of the phosphor powder. As such, in the same batch of products, some LEDs may emit yellowish white light while the others produce bluish white light, causing the light emitted from the LED products to migrate within a range between 0.26 and 0.36 as defined by the Chromaticity Coordinates. Similarly, as described in R.O.C. Patent Publication No. 480879 assigned to the present applicant, entitled “Method to Compensate for the Color No Uniformity of Color Display,” the mixed white light emitted from the LED devices that combine RGB LED chips would vary due to the slight diversity of and the possible random errors occurring in the manufacturing processes of respective LED dies.
Furthermore, the luminous intensity of LEDs will diminish over time and the light emitted therefrom will shift in frequency as well. In the case where LEDs with three primary colors are adopted to provide white light, the variation in decaying rates of LEDs gets extensive due to the increased number of LEDs mounted in a backlight. This, together with the factor that different regions of a backlight are usually operated at different environmental temperatures, lead to un-uniformity in brightness and chromaticity among different regions of a backlight and, as a consequence, an LCD-TV or a computer monitor that is provided with the LED backlight may fail to meet the basic quality requirement. Such a defect is intolerable since the human eye is very perceptive.
In order to reduce the differences in brightness and chromaticity among small areas of a backlight caused by aging of individual LEDs and improve the regional un-uniformity in brightness and chromaticity that often occurs in a backlight as a consequence of implementing the dynamic backlight area control technology, some techniques were proposed in the art, in which the overall brightness and overall chromaticity of an entire backlight are enhanced by weighting the measured values and elevating the total power supply to the backlight based on the weighted values. However, the enhancement of the overall brightness cannot effectively overcome the problem of brightness loss due to decay of individual LEDs. The regional brightness enhancement proposed in the prior art also fails to compensate for the chromaticity deviation caused by wavelength shift of the light emitted from individual LEDs.
In order to deal with the drawbacks described above, R.O.C. Patent Publication No. 480879, entitled “Method to Compensate for the Color No Uniformity of Color Display,” has proposed a concept of “virtually primary color,” by which the brightness loss and chromaticity deviation of a light source can be successfully compensated for. However, the patent does not focus on the efficiency of detection itself.
Other solutions to the problem of brightness loss and chromaticity deviation of LEDs mounted in a backlight were also reported lately. For example, as proposed in US2006/049781 issued to Agilent Technologies Inc., entitled “Use of a Plurality of Light Sensors to Regulate a Direct-Firing Backlight for a Display,” a direct-type backlight 1 of a display device as shown in FIG. 1 is configured to include a plurality of light emitting regions 10 , each having at least one LED 12 . A plurality of light sensors 14 are provided such that each of the light sensors 14 is positioned to sense light produced by an LED 12 located in a corresponding light emitting region 10 . If the luminous intensity of the LED 12 located in the light emitting region 10 diminishes, a processing device 16 in a control system will receive information from the light sensor and regulates light emitted from the backlight.
This method has a major disadvantage in the necessity of using multiple optical sensors. If the backlight includes only a small number of light emitting regions, a precise adjustment of variation in light performance among the regions could never happen. An increased number of the light emitting regions, however, will unfavorably result in a much more complicated structure with an intolerably high manufacture cost. Another disadvantage of the method is that the light emitted from different regions may interfere with one another, causing false detection results.
Another technique was proposed by Sony Corporation in the patent publications entitled “Display Unit and Backlight Unit” and “Apparatus and Method for Driving Backlight Unit”. As shown in FIG. 2 , a backlight 2 disclosed therein is divided into multiple regions 20 of same temperatures according to the temperature distribution of the backlight. Each of the regions 20 is provided with a temperature sensor and a photometric sensor (not shown). Based upon the information of temperature distribution and brightness deviation measured by the sensors, the luminous fluxes of the respective RGB dies can be adjusted to achieve uniformity in brightness and chromaticity.
This technique faces a technical difficulty in that the actual temperature distribution in the backlight 2 may not perfectly correlate to the distribution of regions 20 shown in FIG. 20 . Therefore, if the respective LEDs 200 in the same region 20 are affected by different temperatures or have different degrees of aging or wavelength shift, the brightness and chromaticity levels could not be easily regulated. Another disadvantage of this technique is still the complexity of product designs with increased manufacture cost as a result of using multiple optical sensors and temperature sensors.
Frankly speaking, all of the techniques described above involve a static compensation process based on the presumption that the brightness and chromaticity levels of a backlight are maintained at fixed values. This process allows optical sensors and temperature sensors to real-time detect the brightness and chromaticity levels of a backlight and, if there exists a deviation from a corresponding reference value, provides compensation for the deviation. However, the current LCD backlight technology is advancing to develop the so-called “dynamic control” or “local area control” processes, in which a backlight is divided into multiple regions whose brightness and chromaticity levels are variable with images displayed, thereby achieving high dynamic contrast and great power-saving efficiency. In a backlight with dynamic backlight control, the brightness levels of respective LEDs vary with images displayed and, thus, are unable to be compared with reference values during frame display sections. The comparison can only be done during a blanking time between successive frame display sections.
In addition, since the backlight is mounted at the backside of an liquid crystal display module (which includes a pair of glass substrates, liquid crystal materials, a color filter, a polarizer, conductive glasses and so on), the light originally emitted from the LEDs, after reflected within the body of the display, will arrive at the optical sensor with a brightness value affected by the following factors: (1) the reflection coefficient of each wall of the backlight; (2) the reflection coefficient of each optical surface present within the liquid crystal display module; (3) the degree of opening/closing of the liquid crystal valve; (4) the incident amount of ambient light; and so on. Among these factors, the degree of opening/closing of the liquid crystal valve can be fixed by setting the liquid crystal valve in a certain state during testing. For example, the display panel can be set in a fully dark state to assure that the liquid crystal molecules are in a fully closed state where the amount of reflective or diffusing light originating from a selected LED is fixed.
In order to automatically, efficiently and precisely determine the degree of decay of the respective LEDs mounted in a backlight and compensate for the decay of individual LEDs and maintain the brightness and uniformity of the backlight at a level equivalent to that when the backlight is brand new, R.O.C. Patent Application No. 97108227 owned by the present applicant, entitled “Method for Compensating for the Attenuation of a Liquid Crystal Display Having an LED Backlight and Display That Exhibits an Attenuation Compensating Function,” discloses a “synchronous-phase detection algorithm,” in which a digital signal processor (hereafter, DSP) is employed to manage values detected by optical sensors. As shown in FIG. 3 , the brightness control data (hereafter, BCD) output from the DSP are fixed to have a PWM duty-cycle ratio of 50% and accumulatively scored during the positive and negative phases (namely, carrying out an addition calculation during the period of a positive phase and carrying out a subtraction calculation during the period of a negative phase). For example, assuming that the BCD are transmitted to the PWM generator in the form of 10-bit data (which could present a maximum duty cycle of 100% when BCD=1023), the DSP will output a BCD value of 512, such that the PWM generator is triggered to generate a square wave of 50% High and 50% Low, which is subsequently used for driving an LED to emit light.
Since the basic pulse signals “clock” for the PWM generator come from the output of the DSP, the DSP is able to use a plurality of basic pulse signals to constitute a pulse cycle of a synchronizing signal and make the positive and negative phases in each pulse cycle to have an equal length during test. That is, when the pulse wave is in a half period of High (a positive phase) where the analog switch is in the “ON” state, LEDs are actuated to emit light. With the wave moves to a negative phase during a half period of Low where the analog switch is set in the “OFF” state, the LEDs do not emit light. The light originally emitted from the LEDs, after reflected within the backlight and display panel, will reach a phototransistor with a photocurrent I s that is exactly synchronous with the timing for LED light-emission. During the half periods of High, represented by odd numerals 81 , 83 , 85 . . . , the DSP accumulatively adds up the data transmitted from the A/D converter, while subtracting the data transmitted from the A/D converter during the half periods of Low which are represented by even numerals 82 , 84 , 86 . . . . By way of continuously performing addition/subtraction calculation during positive/negative phases in a synchronous-phase detection algorithm, the detected values during positive phases are gradually added up and augmented, whereas no value can be subtracted from during negative phases due to the absence of light emission from LEDs. As such, the more periods the DSP processes, the bigger the detected values for LED light emission become upon accumulative addition.
In contrast to LED's quick transition between bright and dark states, the signals of ambient light detected by an optical sensor are normally direct-current signals or slowly changing alternative-current signals. When the detected values for ambient light are transmitted into the DSP, the detected signal I n almost remains constant throughout all of the half periods of High 81 , 83 , 85 . . . and Low 82 , 84 , 86 . . . , such that the detected values for ambient light are nearly counterbalanced upon performing addition/subtraction calculation in the DSP during the positive/negative phases. By this way, only the detected values for LED light-emission are left after the processing by the DSP. This will significantly improve the ratio of the detected values for LED light-emission to the detected values for ambient light, so that the possible effects of ambient light may be almost eliminated.
The method described above may reasonably eliminate ambient noises, thereby ensuring that the obtained signals entirely reflect the luminous conditions of LEDs. However, as display devices increase in size, the number of LED dies mounted in a backlight gets greater and so does the number of LEDs to be tested. If the LEDs in a display device are to be tested separately in a one-by-one manner, it would take several seconds to complete the test for all of the LEDs. Given that there exists only a time interval of a few hundred microseconds (μs) between two successive frames, the enormous amount of detection and calculation time needed for testing all of the LEDs in a backlight will be forcedly divided into tiny testing sections hidden between displayed frames. As a result, the first and last tested LEDs may have experienced slightly different environmental changes (such as a variation in temperature) during the test. In other words, the detection and compensation process cannot be precisely performed due to the time-consuming nature of the test.
Therefore, there exists a need for technical means for shortening the time needed for testing a display device having an LED backlight to achieve an optimal correcting effect. The present invention provides the best solution in response to the need.
SUMMARY OF THE INVENTION
Accordingly, a purpose of the present invention is to provide a method for group-by-group detecting the respective degrees of decay of respective LED devices in a liquid crystal display device having an LED backlight by using mutually orthogonal signals and then compensating for the decay.
Another purpose of the invention is to provide a rapid detection method for detecting the respective degrees of decay of respective LED devices in a liquid crystal display device having an LED backlight and then compensating for the decay, without drawing any attention from users.
It is still another purpose of the invention to provide an automatic detection method for detecting the respective degrees of decay of respective LED devices in a liquid crystal display device having an LED backlight and then compensating for the decay.
It is still another purpose of the invention to provide a liquid crystal display device having an LED backlight that is capable of precisely detecting the respective degrees of decay of respective LED devices mounted therein and then compensating for the decay.
It is still another purpose of the invention to provide a liquid crystal display device having an LED backlight that is capable of automatically detecting the respective degrees of decay of respective LED devices mounted therein and then compensating for the decay.
It is yet still another purpose of the invention to provide a liquid crystal display device having an LED backlight that is capable of rapidly detecting the respective degrees of decay of respective LED devices mounted therein and then compensating for the decay.
The present invention therefore provides a rapid detection method for the decay of a liquid crystal display device having an LED backlight. The display device comprises a liquid crystal display module and the LED backlight comprises at least one group of LED devices with each group having a plurality of LED devices. The display device is provided with at least one optical sensor, a power supplying device for separately actuating the respective LED devices with a variable electric output, a processing device for receiving a value detected by said optical sensor and controlling the electric output of said power supplying device, and a memory device that pre-stores the respective reference values for the respective LED devices which are separately obtained by the optical sensor when the respective LED devices are lighted in an one-by-one manner at least one given power level. The method comprises the steps of:
a) at a predetermined starting time point, allowing the processing device to command the power supplying device to cut off the power supply to all of the LED devices;
b) powering the group of LED devices to emit light in a synchronized manner by providing test signal data comprised of a plurality of driving signals, wherein the driving signals are mutually orthogonal to one another and have an output power level corresponding to the at least one given power level stored in the memory device;
c) allowing the optical sensor to detect the emitted light from the group of LED devices supplied with the test signal data to obtain a detected value and converting the detected value into an electrical test signal; and
d) allowing the processing device to extract respective light emission data for the respective LED devices in the group from the electrical test signal and compare the respective light emission data for the respective LED devices with the corresponding reference values pre-stored in the memory device.
The present invention further provides a liquid crystal display device having an LED backlight that is provided with a rapid compensating device for decay. The display device comprises: a liquid crystal display module; an LED backlight having plural groups of LED devices with each of the groups having a plurality of LED devices; at least one optical sensor mounted in the backlight; a power supplying device for separately actuating the respective LED devices with a variable electric output; a memory device that pre-stores the respective reference values for the respective LED devices which are separately obtained by the optical sensor when the respective LED devices are lighted in an one-by-one manner at least one given power level; and a processing device for driving the power supplying device at a predetermined time point to provide test signal data comprised of a plurality of driving signals, such that one group of the plural groups of LED devices are powered to emit light in a synchronized manner, wherein the driving signals are mutually orthogonal to one another and have an output power level corresponding to the at least one given power level stored in the memory device; and for receving the values detected by the optical sensor upon receiving the emitted light from the group of LED devices; and for extracting respective light emission data for the respective LED devices in the group and comparing the respective light emission data with the corresponding reference values pre-stored in the memory device; and for varying the electric output of the power supplying device to the respective LED devices if the respective light emission data for the respective LED devices deviate from the corresponding pre-stored reference values beyond a predetermined deviation.
In conclusion, by virtue of the invention disclosed herein, the external optical noise and interference can be effectively eliminated and the degree of decay of individual LED devices can be detected in a precise and rapid manner and the decay thereof can be compensated for in a timely manner, such that the uniformity, brightness and chromaticity in all areas of a display are ensured to be as good as brand new.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and effects of the invention will become apparent with reference to the following description of the preferred embodiments taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram illustrating a conventional direct-type backlight mounted in a display device, wherein the backlight is adjusted by a plurality of optical sensors;
FIG. 2 is a schematic diagram illustrating a conventional display unit, a conventional backlight unit and a conventional apparatus for driving the backlight unit;
FIG. 3 is a diagram of BCD period disclosed in a patent application owned by the applicant, entitled “Method for Compensating for the Attenuation of a Liquid Crystal Display Having an LED Backlight and Display That Exhibits an Attenuation Compensating Function”;
FIG. 4 is a schematic diagram illustrating the structure of a liquid crystal display device having an LED backlight provided with a rapid compensating device for decay according to the invention;
FIG. 5 is a schematic diagram showing the LED backlight according to the invention, in which LED devices are divided into groups;
FIG. 6 is a schematic diagram showing the LED backlight according to the invention, in which LED devices are divided into groups, with each group including a plurality of LED devices;
FIG. 7 is a schematic diagram illustrating an optical sensor disposed in the LED backlight according to the invention;
FIG. 8 is an enlarged schematic view illustrating a group of LED devices mounted in the LED backlight according to the invention;
FIG. 9 is a flow chart showing the procedure of testing the respective LED devices mounted in the LED backlight according to the invention;
FIG. 10 is a schematic diagram showing a plurality of color-photometry sensors mounted in the LED backlight and used for detecting red, green and blue light, respectively;
FIG. 11 is a schematic diagram illustrating an LED backlight according to the invention, in which a solar cell is shown to serve as an optical sensor;
FIG. 12 is an enlarged schematic view illustrating a group of LED devices mounted in the LED backlight according to the invention, in which the group comprises a plurality of LED light sources, each being made up of R, G and B LED dies; and
FIG. 13 is a schematic diagram showing a compensation processing over LED reaction time.
DETAILED DESCRIPTION OF THE INVENTION
Normally, the blanking times between successive frame display sections may only sum up to approximately 5% of the overall operation period. For a display that essentially shows 60 frames per second, a blanking time takes roughly 0.8 ms. A gist of the invention is to accomplish the correction and compensation for the poor performance of a display device during the blanking times by using an appropriate small number of optical sensors.
Referring to FIG. 4 , the inventive liquid crystal display having an LED backlight provided with a rapid compensation device for decay includes a liquid crystal module 31 , an LED backlight 32 , an optical sensor 33 , a power supplying device 34 , a memory device 35 and a processing device 36 .
In order to manifest the advantages of the invention, a single optical sensor is employed in this embodiment to illustrate the way in which an optical sensor may be utilized to read and detect the light-emitting conditions of respective LED devices. As shown in FIG. 5 , the entire LED backlight 32 may by way of example include a total of 3600 LED devices, which are arranged into 225 groups designated G 1 , G 2 , . . . G 225 , with each group having 16 LEDs. As illustrated by G 1 in FIG. 6 , each group of LED devices may include white-light LEDs 301 , 302 , 303 , . . . 316 . The respective LED devices are electrically connected to a constant current source I S via separate operable switch elements 321 , 322 , 323 , . . . 336 and, therefore, the lighting of the LEDs is determined by ON/OFF control of the switch elements 321 , 322 , 323 , . . . 336 . It is apparent to those skilled in the art that when necessary, a plurality of LEDs (such as three LEDs) may be connected in series to constitute an LED device. In addition, the LED devices in these groups may each be a white-light LED, or a combination of LEDs having different colors, or a single-color LED having for example anyone of R, G and B colors.
During each cycle of applying driving signals, the processing device regulates the ON/OFF states of the respective analog switch elements 321 , 322 , 323 , . . . 336 to trigger tens of switching operations. The processing device further performs PWM (pulse-width modulation) control by regulating the ratio of ON period to OFF period in each switching operation. As shown in FIG. 7 , a phototransistor is disposed at an appropriate position within a LED backlight 32 to serve as an optical sensor 33 for receiving the light originally emitted from the LED backlight 32 and reflected back by the liquid crystal module.
In a normal image display mode, image data are supplied to the liquid crystal module and the LED backlight 32 is powered to emit light towards the liquid crystal module for displaying images. During the time, the PWM control values for the respective LED devices 301 , 302 , 303 , . . . 316 are determined by the control device according to the image data supplied from outside. In other words, the ON/OFF states of the respective operable switch elements 321 , 322 , 323 , . . . 336 are determined according to the bright and dark states of the images displayed, so as to achieve the so-called “local dimming control”.
Since the brightness of an LED may change with temperature and decay over time and the light emitted therefrom may also shift in wavelength, the blanking times between successive frame display sections, in which no image data are provided, are used in this embodiment as time points for detecting the light-emitting conditions of the respective LED devices in the backlight.
Accordingly, the invention is primarily characterized in that during the detection time points described above, the respective LED devices in a given group are simultaneously driven to emit light in response to receipt of test signal data comprised of multiple driving signals orthogonal with respect to one another. For illustrative purpose, the test signal data are referred to as a “mutually orthogonal” series. The supplied power is encoded into mutually orthogonal driving signals, each of which is used to modulate an LED device. The total number of the “mutually orthogonal” driving signals should be at least equal to the number of the LED devices in the given group, so that any of the driving signals will not repeat itself, wherein each of the driving signals A i (n) is a permutation of digits 1 and −1 and satisfies the following equations:
∑
n
=
1
N
A
i
(
n
)
=
0
(
1
≤
n
≤
N
)
,
Equation
(
1
)
∑
n
=
1
N
A
i
2
(
n
)
=
N
,
and
Equation
(
2
)
∑
n
=
1
N
A
i
(
n
)
A
j
(
n
)
=
0
(
i
≠
j
)
.
Equation
(
3
)
If each of the digits 1 and −1 is defined to be a bit and each of the driving signals is defined to be a byte, then N represents the number of bits in a byte and from there “mutually orthogonal” series with various bit numbers N may be obtained using Walsh matrix method. When N=2K, the maximum possible number of distinct driving signals in a “mutually orthogonal” series is N−1. For example, when N=4, the “mutually orthogonal” series of driving signals that may be obtained are as follows:
A 1 =(1, −1, 1, −1), A 2 =(1, 1, −1, −1), and A 3 =(1, −1, −1 , 1).
The three driving signals described above are substituted into
Equations (1), (2) and (3) to give the following equations:
∑
n
=
1
4
A
i
(
n
)
=
0
;
∑
n
=
1
4
A
i
2
(
n
)
=
4
;
and
∑
n
=
1
4
A
i
(
n
)
A
j
(
n
)
=
0
(
i
≠
j
)
.
Similarly, if the bit number N=8, the resultant “mutually orthogonal” series of seven driving signals are as follows:
A 1 =(1 −1 1 −1 1 −1 1 −1), A 2 =(1 1 −1 −1 1 1 −1 −1), A 3 =(1 −1 −1 1 1 −1 −1 1), A 4 =(1 1 1 1 −1 −1 −1 −1), A 5 =(1 −1 1 −1 −1 1 −1 1), A 6 =(1 1 −1 −1 −1 −1 1 1), and A 7 =(1 −1 −1 1 −1 1 1 −1).
It is indicated by calculation that the seven driving signals similarly satisfy the equations
∑
n
=
1
8
A
i
(
n
)
=
0
;
∑
n
=
1
8
A
i
2
(
n
)
=
8
;
and
∑
n
=
1
8
A
i
(
n
)
A
j
(
n
)
=
0
(
i
≠
j
)
.
A driving signal in a “mutually orthogonal” series is orthogonal with respect to the rest of driving signals in the same series, namely,
∑ n = 1 N A i ( n ) A j ( n ) = 0 ( i ≠ j ) .
As such, even if the respective LED devices in the same group are simultaneously powered to light and detected by a single optical sensor 33 , the driving signals can still be retrieved and read out by demodulation according to the method described below. The respective LED devices in the same group will not interfere with one another and are subjected to multiple access at the same time. The multiple access leads to a 2-fold, 4-fold, 8-fold, 16-fold, 32-fold . . . increase in test rate as compared to the conventional process in which LED devices are tested in an one-by-one manner.
According to the invention, a bit value of +1 in a driving signal represents a PWM control switch being in the ON state where a corresponding LED device is powered to emit light, whereas a bit value of −1 represents the control switch being OFF. It is assumed that the light emitted from a given LED i has a value I i as detected by the optical sensor 33 when the PWM control switch associated with the LED i is ON, and that the value will turn to zero when the control switch is switched to its OFF state. If a group of LED devices are modulated by test signal data comprised of a certain “mutually orthogonal” series of driving signals A i (n), then the light emitted from the LED i device as driven by the test signals A i (n) is detected in a clock sequence of n=1, . . . N to have values equal to ½I i (1+A i (n))(n=1, 2, . . . N), respectively.
Therefore, provided that the group G 1 of LED devices 301 , 302 , 303 , . . . 316 , each being made up of a single direct-type LEDs as shown in FIG. 8 , are powered and modulated by a “mutually orthogonal” series of driving signals A 1 (n), A 2 (n) . . . A 16 (n) with each PWM control signal C i =½(1+A i (n)), (n=1, 2, . . . 6), and that the light emitted from an LED is detected to have a value of I i (i=1, 2, . . . 16), and that the number of bits in a byte is set to 32 so that the “mutually orthogonal” series of driving signals are numbered to be no less than 16, the total light detected by the optical sensor in a clock sequence of n=1, 2, . . . 32 will have a detected value
S
(
n
)
=
∑
i
=
1
16
I
i
C
i
(
n
)
=
∑
i
=
1
16
1
2
I
i
(
1
+
A
i
(
n
)
)
,
(
n
=
1
,
2
…
32
)
.
Next, a signal processor DSP is used to analog/digital (A/D) convert and demodulate the total detected value S(n) into the optical detected values for the respective LED devices 301 , 302 , 303 , . . . 316 . For example, the optical detected value I 1 for the LED device 301 can be demodulated from S(n) by allowing the DSP to process
∑ n = 1 32 S ( n ) A 1 ( n ) ,
in view of the relationship
∑
n
=
1
32
S
(
n
)
A
1
(
n
)
=
∑
n
=
1
32
∑
i
=
1
16
1
2
(
1
+
A
i
(
n
)
)
I
i
·
A
1
(
n
)
=
1
2
∑
n
=
1
32
∑
i
=
1
16
I
i
A
1
(
n
)
+
1
2
∑
n
=
1
32
∑
i
=
1
16
I
i
A
i
(
n
)
A
1
(
n
)
=
1
2
∑
i
=
1
16
I
i
∑
n
=
1
32
A
1
(
n
)
+
1
2
∑
i
=
1
16
I
i
∑
n
=
1
32
A
i
(
n
)
A
1
(
n
)
=
1
2
∑
i
=
1
16
I
i
·
0
+
1
2
∑
i
=
1
16
I
i
δ
i
1
·
32
=
0
+
1
2
I
1
·
32
=
16
I
1
,
and
gives
I
1
=
1
16
∑
n
=
1
32
S
(
n
)
A
1
(
n
)
.
Similarly, the DSP processing of
∑ n = 1 32 S ( n ) A 2 ( n )
gives 16 I 2 .
Therefore, from the sum values S 1 , S 2 , S 3 , . . . S 32 detected by the optical sensor, the respective detected values for the 16 LED devices 301 , 302 , 303 , . . . 316 can be obtained based upon the relationship
I
k
=
1
16
∑
n
=
1
32
S
(
n
)
A
k
(
n
)
.
In particular, a “mutually orthogonal” series of driving signals are used to modulate the respective devices, and the respective driving signals in the “mutually orthogonal” series are subsequently used to multiply with the total detected values to accomplish a synchronized demodulation. Given that the synchronized demodulation algorithm includes a step of multiplying the respective driving signals back with the total detected values, and that each of the driving signals has exactly half of the bit values equal to +1 and the other half equal to −1, the ambient signals which are asynchronous with the driving signals and interfere with the detected result of the optical sensor will be demodulated in clock sequence during the demodulation process, with half of them being multiplied with +1 and the other half with −1. The adverse effects caused by the ambient signals are significantly reduced after processing, and this is particularly true as the bit number in a driving signal byte increases. Therefore, the embodiment disclosed herein may further perform an anti-noise function.
An elongated sequence of a driving signal (i.e., an increased length of a byte) increases effectively the signal-to-noise ratio, thereby facilitating the anti-interference function. The interference described herein may come from ambient light. For example, when sunlight radiates to an indoor display device, an optical sensor mounted in the display device may be interfered to generate an ambient signal N s . As a consequence, the total detected value by the optical sensor turns out to be S(n)+N s . If the total detected value is demodulated by A i (n), the resultant demodulated signals would be as good as the signals obtained in the absence of the ambient signal, provided that
∑
n
=
1
32
N
s
A
i
(
n
)
=
0.
It is readily apparent to those skilled in the art that a “mutually orthogonal” series of driving signal sequences can be extended in length or, in other words, the number of bits in a byte can be increased by repeating the original signal bytes several times. For instance, assuming that the number of bits in an original byte is 8, the byte can be easily multiplied by repeating the 8 bits in the same order. In this case, the driving signals from A 1 to A 7 as described above may turn into a series of 16-bit signals by duplicating themselves:
A 1 ′=(1 −1 1 −1 1 −1 1 −1, 1 −1 1 −1 1 −1 1 −1) A 2 ′=(1 1 −1 −1 1 1 −1 −1, 1 1 −1 −1 1 1 −1 −1) (The same processing is performed to obtain A 3 ′ to A 6 ′.) A 7 ′=(1 −1 −1 1 −1 1 1 −1, 1 −1 −1 1 −1 1 1 −1).
Meanwhile, the characteristic “mutually orthogonal” relationship among A 1 ′, A 2 ′, . . . A 7 ′ remains the same. That is to say, Equations (1) and (3) are kept unchanged and only the number of digits in Equation (2) is doubled as compared to the original, namely,
∑ n = 1 16 A i 2 ( n ) = 16.
The use of driving signals having a longer sequence (i.e., having a larger bit number) for executing modulation will remarkably elevate the anti-interference ability during test, but would disadvantageously double the time for testing a given group of LEDs.
It is found by substituting actual values into the examples above that a bit cycle would be 1 μs, if the bit frequency is set to 1 MHz. When the length of a driving signal corresponds to a byte including n=64 bits, to test a total of 3600 LED devices mounted in a backlight of a display device in an one-by-one manner takes 3600×64 μs which is equal to 230.4 ms, despite achieving a 64-fold increase in anti-interference ability. For a display that shows 60 frames per second and each frame takes 16.6 ms to display, in which the blanking times between successive frame display sections only sum up to 5% of the overall operation period and a blanking time takes roughly 0.8 ms, a total of 288 blanking times are needed to complete the test. In other words, it takes around 4.8 seconds to test the entire display device if the total blanking time per second is 60.
In contrast, the embodiment disclosed herein subjects a group of 16 LED devices to a synchronized test. Given that each of the driving signals is 64 bits in length with all bits having the same cycle length, the invention achieves a 16-fold increase in test rate and only 18 blanking times are needed to complete the test. Since a 64-bit byte is exemplified herein for a driving signal, the entire series may include as many as 63 “mutually orthogonal” driving signals, so that the possible number of LED devices that can be lighted and tested synchronously is increased to 60 per group. As a result, a complete test can be done by using only 5 blanking times and within 1/12 sec.
Referring to the flow chart shown in FIG. 9 , and according to the embodiment disclosed herein, in Step 711 , the LED devices mounted in a backlight of a display device are powered to light at least one given power level before the display device leaves the plant, and then in Step 713 , the lighting conditions of the LED devices at the at least one given power level are detected by a optical sensor. In Step 715 , the detected brightness and chromaticity levels of the respective LED i devices mounted in the backlight are recorded as standard detected values I si .
Next, in Step 721 according to the flow chart described above, the processing device first gives a command in the blanking times to terminate the power supply to all of the LED devices mounted in the backlight, such that the LED devices under test will not be interfered by the rest of LED devices mounted in the backlight. In Step 722 , the “mutually orthogonal” series of driving signals described above are then provided as test signal data for powering a given group of LED devices to light in batch mode, wherein the driving signal received by any given LED device in the group is orthogonal with respect to the driving signals received by the rest of the LED devices in the same group. Therefore, the number of the mutually orthogonal driving signals should be at least equal to the number of LED devices in the group.
In Step 732 , an optical sensor is provided to detect the overall light emission from the group of LED devices powered by the test signal data and convert the detected value into an electrical test signal which is in turn transmitted to the processing device. In Step 724 , the processing device multiplies the respective driving signals with the electrical test signal according to the embodiments described above, such that the electrical test signal is demodulated to obtain the luminous data of the respective LED devices. The obtained luminous data are then compared with the corresponding detected values pre-stored in a memory device (namely, the standard detected values I si for the respective LED devices). For example, if a demodulated detected value I i deviates from the corresponding standard detected value I si beyond a predetermined deviation, such as a 5% deviation in brightness, adjustment data would be obtained by calculation in Step 725 for compensation for the deviation, such that the deviation is compensated for by adjusting the PWM driving value for the LED i during the subsequent frame display sections.
In general, a ratio of the standard detected value I si to the demodulated detected value I i , namely, (I si /I i ), can serve as a PWM ratio for the corresponding LED. Since the comparison of the respective LED devices is based upon the data obtained by the same optical sensor, any deviation in the luminous conditions of the respective LED devices, regardless of resulting from variation in ambient temperature or differential aging of the LED devices, can be successfully compensated for such that the detected values of the respective LED devices are restored to a level equal to the standard detected values measured when the display device is ready to leave the plant. According to the inventive process, the brightness and chromaticity of the LED devices can be adjusted to achieve sufficient uniformity, and the quality of the backlight can be restored to a level comparable with the original quality that the backlight has when it is ready to leave the plant.
In this embodiment, the group-by-group testing procedure for LED devices is continuously carried out during the blanking times by the processing device until Step 726 confirms that all of the groups have been tested. According to the technique disclosed herein, the test and compensation described above can be achieved within a short period of time. Therefore, in Step 727 , the procedure from Step 721 to Step 726 may be repeated whenever the display device is consecutively operated for a given period of time, such as for an hour, so as to ensure the display quality of the display device at all time. As an alternative, the test and compensation procedure according to the invention may continuously perform throughout the operation of the display device by taking advantage of its time-saving features, thereby ensuring that the display quality of the display device is as good as brand new.
The sensitivity of an optical sensor may change slightly at different temperatures. However, this only affects the absolute brightness values detected by the optical sensor and presents no effect on the relative detected values for the LED devices. That is to say, there may be a slight change in the absolute brightness values, but the uniformity in relative brightness and chromaticity levels remains unchanged. If desired, optical sensors equipped with an internal temperature compensation circuit may be employed in the invention to obtain the exact brightness values free of temperature effect.
The phototransistor used in the previous embodiments is not the only option for the optical sensor according to the invention. Additional examples of the optical sensor include color-photometry sensors 33 R, 33 G and 33 B which, as illustrated in FIG. 10 , are mounted in a backlight for detecting red, green and blue lights, respectively, or a solar cell 33 ′ shown in FIG. 11 . The optical sensor(s) may be further assisted by a voltage amplifier for amplifying the values detected by the optical sensor and an analog/digital converter for converting the electrical signals output from the voltage amplifier, thereby converting the detected data for groups of LED devices into digital signals and transmitting the same to the processing device.
Furthermore, according to the embodiment shown in FIG. 12 , a light source group G 1 comprises a plurality of “three-in-one” LED light sources, each being made up of intimately disposed R, G and B LED dies. However, the disposition of R, G and B LED dies in the same light source may give rise to an undesired change in overall brightness and chromaticity levels of the light source as compared to those when the display device leaves the plant due to their differences in decay rate and response to ambient temperature. Further, some advanced high-level applications in display devices are premised upon successful compensation not only for loss of brightness but also for chromaticity deviation caused by wavelength shift of the emitted light. Therefore, the 33 R optical sensor of this embodiment is selected to have a spectral responsibility close to the standard response function X (λ) according to the CIE 1931 standard colorimetric system, whereas the 33 G optical sensor has spectral responsibility close to the standard response function y (λ) and the 33 B optical sensor has spectral responsibility close to the standard response function Z (λ). In this embodiment, the R, G and B LED dies disposed in the same LED light source are each associated with a separate PWM control switch and, hence, are each considered as an LED device for test.
As described above, before leaving the plant, the respective LED light sources in this embodiment are detected under a certain standard condition by a “standard photo-detector” to determine the tri-stimulus values thereof, which are designated as X 1r , X 2r , X 3r ; and X 1g , X 2g , X 3g ; and X 1b ), X 2b , X 3b , respectively. The nine stimulus values represent the brightness and chromaticity levels necessary for achieving standard white light, wherein X 10 =X 1r +X 1g +X 1b serves as the X stimulus value for white light, X 20 =X 2r +X 2g +X 2b serves as the Y stimulus value for white light and X 30 =X 3r +X 3g +X 3b serves as the Z stimulus value for white light. The nine stimulus values are recorded in a memory device.
Subsequent to mounting the finished backlight to a display panel, the respective R, G and B dies are measured for the standard detected values under a standard environment provided in the plant (such as at a constant temperature of 25° C. and at a well-ventilated site) in a manner described above by the color-photometry sensors 33 R, 33 G and 33 B mounted in the backlight, optionally using a “mutually orthogonal” series of driving signals to carry out the so-called multiple access as described in previous paragraphs to thereby test the LED dies in batch mode. Assuming that the first light source in the group G 1 comprises three LED dies r 1 , g i and b 1 , the lights emitted from which present optical detected values of x 1r , x 2r , x 3r ; and x 1g , x 2g , x 3g ; and x 1b , x 2b , x 3b by the color-photometry sensors 33 R, 33 G and 33 B, respectively. A linear relationship exists between the nine detected values x ij and the nine stimulus values X ij measured by the “standard photo-detector,” which can be described by the following equation:
x ij = K ij ·X ij ( i= 1, 2, 3; j=r, g, b ) (4).
Assuming that the light emitted from the LED dies r 1 , g 1 and b 1 changes in brightness and chromaticity under a certain operation environment due to variation in ambient temperature or differential decay over time, the optical detected values measured by the color-photometry sensors 33 R, 33 G and 33 B during the test are deviated to a value x ij ′(i=1, 2, 3; j=r, g, b), wherein x 1r ′, x 2r ′, and x 3r ′ are the values detected by the color-photometry sensors 33 R, 33 G and 33 B upon receiving the light emitted from the LED die r 1 , and the rest can be reasoned out by analogy. Given that the stimulus values are proportional to the optical detected values, the stimulus values of the three LED dies r 1 , g 1 and b 1 can be described by the following equation:
X
ij
′
=
x
ij
′
x
ij
X
ij
(
i
=
1
,
2
,
3
;
j
=
r
,
g
,
b
)
.
(
5
)
If the red, green and blue LED dies, when leaving the plant, may together generate white light by being supplied with predetermined power levels having the PWM values of P r , P g and P b , respectively, the PWM driving values P r ′, P g ′ and P b ′ now become necessary to be provided to the respective LED dies for restoring the brightness and chromaticity levels back to those measured when the LED dies leave the plant. Given that the three stimulus values X, Y and Z remain constant, the relationship can be described by the following equations:
P r ′X 1r ′+P g ′X 1g ′+P b ′X 1b ′=P r X 1r +P g X 1g +P b X 1b ;
P r ′X 2r ′+P g ′X 2g ′+P b ′X 2b ′=P r X 2r +P g X 2g +P b X 2b ; and
P r ′X 3r ′+P g ′X 3g ′+P b ′X 3b ′=P r X 3r +P g X 3g +P b X 3b (6).
By substituting the equations above into Equation (5), it gives the following equations:
P
r
′
x
1
r
′
x
1
r
X
1
r
+
P
g
′
x
1
g
′
x
1
g
X
1
g
+
P
b
′
x
1
b
′
x
1
b
X
1
b
=
P
r
X
1
r
+
P
g
X
1
g
+
P
b
X
1
b
;
P
r
′
x
2
r
′
x
2
r
X
2
r
+
P
g
′
x
2
g
′
x
2
g
X
2
g
+
P
b
′
x
2
b
′
x
2
b
X
2
b
=
P
r
X
2
r
+
P
g
X
2
g
+
P
b
X
2
b
;
and
P
r
′
x
3
r
′
x
3
r
X
3
r
+
P
g
′
x
3
g
′
x
3
g
X
1
g
+
P
b
′
x
3
b
′
x
3
b
X
3
b
=
P
r
X
3
r
+
P
g
X
3
g
+
P
b
X
3
b
.
(
7
)
In Equation (7), the stimulus values X ij are available in the plant, and the values P r , P g and P b are known since the brightness and chromaticity of white light are set constant, and the detected values x ij are also available by measurement under the standard environment provided in the plant. If the values x ij ′ are determined by the optical sensors, fresh PWM driving values P r ′, P g ′ and P b ′ could be obtained using Equation (7). The fresh PWM driving values may then be employed to restore the brightness and chromaticity levels of the light emission from the LED dies r 1 , g 1 and b 1 back to those measured when the LED dies leave the plant.
Furthermore, according to the invention, all of LED devices mounted in a backlight, such as a total number of 3600 LED devices, can be tested within a short period of time, such as 60×64 μs=3.84 ms, which is much shorter than the normal time interval 16.6 ms necessary for displaying an image frame. As shown in FIG. 13 , only a short interval of time Pt is “stolen” from a frame display period T, during which all of the LED devices are forcedly turned off for such an extremely short while that all of the LED devices are tested as described above without drawing any attention from viewers, thereby maintaining the brightness and chromaticity of the display device. The shortened time interval Pr for displaying the image frame still exceeds three-fourth of the original frame display period T. At a display rate of 60 frames per second, the omission of displaying one-fourth of a frame for every 60 frames is substantially unnoticeable by human eyes.
In the case where a deviation in the brightness or chromaticity of a certain LED die cannot be easily compensated for, the processing device will alternatively manage the light emission from the LED devices nearby by commanding the power supplying device to alter the power supply to the nearby LED devices and adjusting the power levels supplied to these LED devices, thereby compensating for the deviation in the overall brightness and chromaticity of the display device.
In conclusion, the invention disclosed herein cannot only perform a rapid test for the luminous effect of respective LED devices but also accomplish the correction and compensation for the poor display performance of a display device, thereby achieving the primary purposes of the invention.
While the invention has been described with reference to the preferred embodiments above, it should be recognized that the preferred embodiments are given for the purpose of illustration only and are not intended to limit the scope of the present invention and that various modifications and changes, which will be apparent to those skilled in the relevant art, may be made without departing from the spirit and scope of the invention. For instance, the power supplying device may by way of example comprise a pulse width modulation circuit or a programmable power source. The memory device may include a non-volatile memory device (EEPROM) or a flash memory device.
|
The invention relates to a rapid detection method for the decay of a liquid crystal display device having an LED backlight and a display device provided with a rapid compensating device for decay. The invention employs a mutually orthogonal series of driving signals to drive a plurality of LED devices in a synchronized manner with the driving signals having a one-to-one correspondence with the LED devices. A processing device extracts respective light emission data for the respective LED devices, compares the respective light emission data with the corresponding reference values pre-stored in the memory device and commands another device to compensate for any deviation existing therebetween. Accordingly, the LED devices are tested in batch mode and the testing is remarkably speeded up without interfering with users' activities.
| 6
|
This application is a divisional of U.S. patent application Ser. No. 12/185,600 filed Aug. 4, 2008.
The invention relates to chemical mechanical polishing of semiconductor wafer materials. More particularly, the invention relates to a chemical mechanical polishing composition and methods for polishing metal interconnects on semiconductor wafers in the presence of dielectrics and barrier materials using the chemical mechanical polishing composition.
Typically, a semiconductor wafer is a wafer of silicon with a dielectric layer containing multiple trenches arranged to form a pattern for circuit interconnects within the dielectric layer. The pattern arrangements usually have a damascene structure or dual damascene structure. A barrier layer covers the patterned dielectric layer and a metal layer covers the barrier layer. The metal layer has at least sufficient thickness to fill the patterned trenches with metal to form circuit interconnects.
Chemical mechanical polishing processes often include multiple polishing steps. For example, a first step removes excess interconnect metals, such as copper at an initial high rate. After the first step removal, a second step polishing can remove metal that remains on the barrier layer outside of the metal interconnects. Subsequent polishing removes the barrier from an underlying dielectric layer of a semiconductor wafer to provide a planar polished surface on the dielectric layer and the metal interconnects.
The metal in a trench or trough on the semiconductor substrate provides a metal line forming a metal circuit. One of the problems to be overcome is that the polishing operation tends to remove metal from each trench or trough, causing recessed dishing of such metal. Dishing is undesirable as it causes variations in the critical dimensions of the metal circuit. To reduce dishing, polishing is performed at a lower polishing pressure. However, merely reducing the polishing pressure would require that polishing continue for a lengthened duration. However, dishing would continue to be produced for the entire lengthened duration.
U.S. Pat. No. 7,086,935 (Wang) describes the use of an abrasive-free copper formulation containing methyl cellulose, an acrylic acid/methacrylic acid copolymer, benzotriazole (BTA) and miscible solvent for patterned wafers. The formulation taught and described by Wang is capable of removing and clearing copper with low copper dishing, but during rapid polishing, the formulation precipitates a green Cu-BTA compound on the polishing pad and wafer. These precipitates require a post-polishing cleaning of the polishing pad to avoid a decrease in polishing removal rate associated with the gum-like precipitate; and they require a post-polishing cleaning of the wafer to avoid defect creation. Such additional cleaning steps require strong and costly cleaning compounds and have an associated “cost of ownership” arising from the delayed wafer throughput.
Hence, there remains a need for chemical mechanical polishing compositions capable of high removal rates with low dishing and that leave a surface clear of interconnect metal residue after a short second step polishing time.
In one aspect of the present invention, there is provided a chemical mechanical polishing composition useful for chemical mechanical polishing of a patterned semiconductor wafer containing a copper interconnect metal, comprising: 0.01 to 15 wt % of an inhibitor for the copper interconnect metal; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; and water; wherein the chemical mechanical polishing composition has an acidic pH.
In another aspect of the present invention, there is provided a chemical mechanical polishing composition useful for chemical mechanical polishing of a patterned semiconductor wafer containing a copper interconnect metal, comprising: 0.01 to 15 wt % of an inhibitor for the copper interconnect metal; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; 0.05 to 20 wt % of a water soluble acid compound of formula I as follows:
wherein R is a hydrogen or a carbon-containing compound; 0.01 to 15 wt % of a complexing agent for the copper interconnect metal; 0.01 to 15 wt % of a phosphorus compound; 0 to 25 wt % of an oxidizer; and water; wherein the chemical mechanical polishing composition has an acidic pH.
In another aspect of the present invention, there is provided a chemical mechanical polishing composition useful for chemical mechanical polishing of a patterned semiconductor wafer containing a copper interconnect metal, comprising: an inhibitor for the copper interconnect metal; 0.001 to 15 wt % of a water soluble cellulose; 0.05 to 20 wt % of a water soluble acid compound of formula I as follows:
wherein R is a hydrogen or a carbon-containing compound; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; 0.01 to 15 wt % of a complexing agent for the copper interconnect metal; 0.01 to 15 wt % of a phosphorus compound; 0 to 25 wt % of an oxidizer; and water; and wherein the chemical mechanical polishing composition has an acidic pH.
In another aspect of the present invention, there is provided, a chemical mechanical polishing composition useful for chemical mechanical polishing of a patterned semiconductor wafer containing a nonferrous metal, comprising: 0.01 to 15 wt % of an inhibitor for the nonferrous metal; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; and water; wherein the chemical mechanical polishing composition has an acidic pH.
In another aspect of the present invention, there is provided a chemical mechanical polishing composition useful for chemical mechanical polishing of a patterned semiconductor wafer containing a nonferrous metal, comprising: an inhibitor for the nonferrous metal; 0.001 to 15 wt % of a water soluble cellulose; 0.05 to 20 wt % of a water soluble acid compound of formula I as follows:
wherein R is a hydrogen or a carbon-containing compound; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; 0.01 to 15 wt % of a complexing agent for the nonferrous metal; 0.01 to 15 wt % of a phosphorus compound; 0 to 25 wt % of an oxidizer; and water; wherein the chemical mechanical polishing composition has an acidic pH.
In another aspect of the present invention, there is provided a method for chemical mechanical polishing of a semiconductor wafer containing a nonferrous metal, comprising: (a) providing a chemical mechanical polishing composition comprising 1 to 25 wt % of an oxidizer; 0.01 to 15 wt % of an inhibitor for the nonferrous metal; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; and water; wherein the chemical mechanical polishing composition has an acidic pH; (b) providing a chemical mechanical polishing pad; (c) providing a semiconductor wafer containing the nonferrous metal; (d) creating dynamic contact between the chemical mechanical polishing pad and the semiconductor wafer and (e) dispensing the polishing solution at or near the interface between the chemical mechanical polishing pad and the semiconductor wafer.
In another aspect of the present invention, there is provided a method for chemical mechanical polishing of a semiconductor wafer containing a nonferrous metal, comprising: (a) providing a chemical mechanical polishing composition comprising an oxidizer; an inhibitor for the nonferrous metal; 0.001 to 15 wt % of a water soluble cellulose; 0.05 to 20 wt % of a water soluble acid compound of a formula I as follows:
wherein R is a hydrogen or a carbon-containing compound; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; 0.01 to 15 wt % of a complexing agent for the nonferrous metal; 0.01 to 15 wt % of a phosphorus compound; 1 to 25 wt % of an oxidizer; and water; wherein the chemical mechanical polishing composition has an acidic pH; (b) providing a chemical mechanical polishing pad; (c) providing a semiconductor wafer containing a nonferrous metal; (d) creating dynamic contact between the chemical mechanical polishing pad and the semiconductor wafer and (e) dispensing the polishing solution at or near the interface between the chemical mechanical polishing pad and the semiconductor wafer.
DETAILED DESCRIPTION
The chemical mechanical polishing composition and method of the present invention provide good metal removal rates, with metal clearing, and low dishing of the metal interconnects when a semiconductor wafer is exposed to chemical mechanical polishing and a chemical mechanical polishing composition containing: an inhibitor; a water soluble modified cellulose; a water soluble acid compound according to formula I:
wherein R is a hydrogen or a carbon-containing compound; a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; optionally, a complexing agent for the copper interconnect metal; optionally, a phosphorus compound; optionally, an oxidizer; and the balance water. The addition of the water soluble acid compound reduces the green staining that is associated with Cu-BTA (Cu +1 ) precipitate.
For purposes of this specification Cu-BTA precipitate includes non-liquids such as solids, gels and polymers and may include Cu +2 ions, spinel precipitates, spinel-like precipitates and impurities. From polishing experience, an insoluble Cu-BTA precipitate forms when the product of copper ion (+1) and BTA concentrations exceed the K sp under the polishing conditions. The precipitation of the Cu-BTA appears to occur in acidic polishing solutions following equilibrium expression (1):
BTAH+Cu + ← (slow) (fast) →Cu-BTA+H + (1)
The chemical mechanical polishing composition of the present invention contains an inhibitor to control removal of nonferrous metal, such as, copper interconnect removal rate by static etch or other removal mechanism. Adjusting the concentration of the inhibitor adjusts the interconnect metal removal rate by protecting the metal from static etch. Preferably, the chemical mechanical polishing composition contains 0.01 to 15 wt % inhibitor. Most preferably, the chemical mechanical polishing composition contains 0.2 to 1.0 wt % inhibitor. In some embodiments, the inhibitor comprises a mixture of inhibitors. In some embodiments, the inhibitor is selected from azole inhibitors, which are particularly effective for polishing wafers having copper and silver interconnects. In some aspects of these embodiments, the inhibitor is selected from benzotriazole (BTA), mercaptobenzothiazole (MBT), tolytriazole (TTA), imidazole and combinations thereof. Combinations of azole inhibitors can increase or decrease the copper removal rate. In some aspects of these embodiments, the inhibitor is BTA, which is a particularly effective inhibitor for copper and silver.
The chemical mechanical polishing composition of the present invention contains a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole. In some embodiments, the chemical mechanical polishing composition contains 0.005 to 5 wt %, preferably 0.05 to 1 wt %, more preferably 0.05 to 0.5 wt %, still more preferably 0.09 to 0.25 wt % of a 9:1 to 1:9, preferably a 5:1 to 1:5, more preferably a 3:1 to 1:3; yet more preferably a 2:1 to 1:2, still more preferably a 1.5:1 to 1:1.5, yet still more preferably a 1.2:1 to 1:1.2, most preferably a 1:1 (on a weight basis) copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole. In some embodiments, the chemical mechanical polishing composition contains 0.005 to 5 wt %, preferably 0.05 to 1 wt %, more preferably 0.05 to 0.5 wt %, still more preferably 0.09 to 0.25 wt % of a 9:1 to 1:9, preferably a 5:1 to 1:5, more preferably a 3:1 to 1:3; yet more preferably a 2:1 to 1:2, still more preferably a 1.5:1 to 1:1.5, yet still more preferably a 1.2:1 to 1:1.2, most preferably a 1:1 (on a weight basis) copolymer of poly(ethylene glycol) methyl ether methacrylate and 1-vinylimidazole. In some embodiments, the chemical mechanical polishing composition contains 0.005 to 5 wt %, preferably 0.05 to 1 wt %, more preferably 0.05 to 0.5 wt %, still more preferably 0.09 to 0.25 wt % of a 9:1 to 1:9, preferably a 5:1 to 1:5, more preferably a 3:1 to 1:3; yet more preferably a 2:1 to 1:2, still more preferably a 1.5:1 to 1:1.5, yet still more preferably a 1.2:1 to 1:1.2, most preferably a 1:1 (on a weight basis) copolymer of poly(ethylene glycol) methyl ether acrylate and 1-vinylimidazole. In some embodiments, the chemical mechanical polishing composition contains 0.005 to 5 wt %, preferably 0.05 to 1 wt %, more preferably 0.05 to 0.5 wt %, still more preferably 0.09 to 0.25 wt % of a 9:1 to 1:9, preferably a 5:1 to 1:5, more preferably a 3:1 to 1:3; yet more preferably a 2:1 to 1:2, still more preferably a 1.5:1 to 1:1.5, yet still more preferably a 1.2:1 to 1:1.2, most preferably a 1:1 (on a weight basis) copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole having a weight average molecular weight, M w , of 5,000 to 1,000,000; preferably 5,000 to 500,000; more preferably 10,000 to 250,000; still more preferably 10,000 to 100,000; yet more preferably 10,000 to 50,000; yet still more preferably 20,000 to 40,000. In some embodiments, the chemical mechanical polishing composition contains 0.005 to 5 wt %, preferably 0.05 to 1 wt %, more preferably 0.05 to 0.5 wt %, still more preferably 0.09 to 0.25 wt % of a 9:1 to 1:9, preferably a 5:1 to 1:5, more preferably a 3:1 to 1:3; yet more preferably a 2:1 to 1:2, still more preferably a 1.5:1 to 1:1.5, yet still more preferably a 1.2:1 to 1:1.2, most preferably a 1:1 (on a weight basis) copolymer of poly(ethylene glycol) methyl ether methacrylate and 1-vinylimidazole having a weight average molecular weight, M w , of 5,000 to 1,000,000; preferably 5,000 to 500,000; more preferably 10,000 to 250,000; still more preferably 10,000 to 100,000; yet more preferably 10,000 to 50,000; yet still more preferably 20,000 to 40,000.
The chemical mechanical polishing composition of the present invention optionally contains a water soluble cellulose. In some embodiments, the chemical mechanical polishing composition contains 0 to 15 wt %; preferably 0.001 to 15 wt %, more preferably 0.005 to 5 wt %, still more preferably 0.01 to 3 wt % water soluble cellulose. In some embodiments of the present invention, the water soluble cellulose is a water soluble modified cellulose modified with a carboxylic acid functionality. Exemplary modified cellulose includes anionic gums such as at least one of agar gum, arabic gum, ghatti gum, karaya gum, guar gum, pectin, locust bean gum, tragacanth gums, tamarind gum, carrageenan gum, and xantham gum, modified starch, alginic acid, mannuronic acid, guluronic acid, and their derivatives and copolymers. In some aspects of these embodiments, the water soluble modified cellulose is carboxy methyl cellulose (CMC). In some aspects of these embodiments, the CMC has a degree of substitution of 0.1 to 3.0 with a weight average molecular weight, M w , of 1,000 to 1,000,000. In some aspects of these embodiments, the CMC has a degree of substitution of 0.7 to 1.2 with a weight average molecular weight of 40,000 to 250,000. For the purposes of this specification, the degree of substitution in CMC is the number of hydroxyl groups on each anhydroglucose unit in the cellulose molecule that is substituted. The degree of substitution can be considered as a measure of the “density” of carboxylic acid groups in the CMC.
The chemical mechanical polishing composition of the present invention optionally contains a water soluble acid compound according to formula I
where R is hydrogen or a carbon-containing compound. These acid compounds are capable of complexing copper ions having a single valency (+1) and divalent (+2) copper ions. During polishing, the water soluble acid compound appears to complex with a sufficient number of copper ions to reduce the formation of Cu-BTA precipitate and control the rate of formation of Cu +2 ions in expression (2) as follows:
2Cu + →Cu 0 +Cu +2 (2)
In some embodiments of the present invention, the chemical mechanical polishing composition contains 0 to 20 wt %; preferably 0.05 to 20 wt %, more preferably 0.1 to 10 wt % water soluble acid compound according to formula I. In some aspects of these embodiments, the chemical mechanical polishing composition contains ≧0.4 wt %, preferably ≧0.4 to 5 wt % water soluble acid compound according to formula I. In some aspects of these embodiments, the water soluble acid compound according to formula I is selected from iminodiacetic acid (IDA); ethylenediaminetetraacetic acid (EDTA); and, combinations thereof. In some aspects of these embodiments, the water soluble acid compound according to formula I is EDTA. In some aspects of these embodiments, the water soluble acid compound according to formula I is IDA.
The chemical mechanical polishing composition of the present invention optionally contains a complexing agent for the nonferrous metal. The complexing agent can facilitate the removal rate of the metal film, such as copper. In some embodiments, the chemical mechanical polishing composition contains 0 to 15 wt %, preferably 0.01 to 15 wt %, more preferably 0.1 to 1 wt % complexing agent. Examplary complexing agents include, for example, acetic acid, citric acid, ethyl acetoacetate, glycolic acid, lactic acid, malic acid, oxalic acid, salicylic acid, sodium diethyl dithiocarbamate, succinic acid, tartaric acid, thioglycolic acid, glycine, alanine, aspartic acid, ethylene diamine, trimethyl diamine, malonic acid, gluteric acid, 3-hydroxybutyric acid, propionic acid, phthalic acid, isophthalic acid, 3-hydroxy salicylic acid, 3,5-dihydroxy salicylic acid, gallic acid, gluconic acid, pyrocatechol, pyrogallol, tannic acid, including, salts and mixtures thereof. In some aspects of these embodiments, the complexing agent is selected from acetic acid, citric acid, ethyl acetoacetate, glycolic acid, lactic acid, malic acid, oxalic acid and combinations thereof. In some aspects of these embodiments, the complexing agent is malic acid.
The chemical mechanical polishing composition of the present invention optionally includes a phosphorus-containing compound. In some embodiments, the chemical mechanical polishing composition comprises 0 to 15 wt %, preferably 0.01 to 15 wt %; more preferably 0.05 to 10 wt %, still more preferably 0.1 to 5 wt %, yet more preferably 0.3 to 2 wt % phosphorous-containing compound. For purposes of this specification, a “phosphorus-containing” compound is any compound containing a phosphorus atom. In some embodiments, the phosphorus-containing compound is selected from a phosphate, pyrophosphate, polyphosphate, phosphonate, including, their acids, salts, mixed acid salts, esters, partial esters, mixed esters, and mixtures thereof. In some aspects of these embodiments, the phosphorus-containing compound is selected from zinc phosphate, zinc pyrophosphate, zinc polyphosphate, zinc phosphonate, ammonium phosphate, ammonium pyrophosphate, ammonium polyphosphate, ammonium phosphonate, diammonium phosphate, diammonium pyrophosphate, diammonium polyphosphate, diammonium phosphonate, guanidine phosphate, guanidine pyrophosphate, guanidine polyphosphate, guanidine phosphonate, iron phosphate, iron pyrophosphate, iron polyphosphate, iron phosphonate, cerium phosphate, cerium pyrophosphate, cerium polyphosphate, cerium phosphonate, ethylene-diamine phosphate, piperazine phosphate, piperazine pyrophosphate, piperazine phosphonate, melamine phosphate, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate, melamine phosphonate, melam phosphate, melam pyrophosphate, melam polyphosphate, melam phosphonate, melem phosphate, melem pyrophosphate, melem polyphosphate, melem phosphonate, dicyanodiamide phosphate, urea phosphate, their acids, salts, mixed acid salts, esters, partial esters, mixed esters, and mixtures thereof. In some aspects of these embodiments, the phosphorus-containing compound is selected from phosphine oxides, phosphine sulphides and phosphorinanes and of phosphonates, phosphites and phosphinates, their acids, salts, mixed acid salts, esters, partial esters and mixed esters. In some embodiments, the phosphorus-containing compound is ammonium phosphate. In some embodiments, the phosphorus-containing compound is ammonium dihydrogen phosphate.
The chemical mechanical polishing composition of the present invention optionally contains an oxidizer. In some embodiments, the chemical mechanical polishing composition contains 0 to 25 wt %, preferably 1 to 25 wt %, more preferably 5 to 10 wt % oxidizer. In some embodiments, the oxidizer is selected from hydrogen peroxide (H 2 O 2 ), monopersulfates, iodates, magnesium perphthalate, peracetic acid and other per-acids, persulfates, bromates, periodates, nitrates, iron salts, cerium salts, Mn (III), Mn (IV) and Mn (VI) salts, silver salts, copper salts, chromium salts, cobalt salts, halogens, hypochlorites and a mixture thereof. In some embodiments, the oxidizer is hydrogen peroxide. When the chemical mechanical polishing composition contains an unstable oxidizing agent such as, hydrogen peroxide, it is preferable to incorporate the oxidizer into the chemical mechanical polishing composition at the point of use.
The chemical mechanical polishing composition of the present invention preferably relies upon a balance of deionized or distilled water to limit incidental impurities.
The chemical mechanical polishing composition of the present invention provides efficacy over a broad pH range. The useful pH range of the chemical mechanical polishing composition of the present invention extends from at 2 to 5. In some embodiments of the present invention, the chemical mechanical polishing composition exhibits a pH of 2 to 5, preferably 2 to 4, more preferably 2.5 to 4 at the point of use. Acids suitable for use adjusting the pH of the chemical mechanical polishing composition of the present invention include, for example, nitric acid, sulfuric acid, hydrochloric acid, and phosphoric acid. Bases suitable for use adjusting the pH of the chemical mechanical polishing composition of the present invention include, for example, ammonium hydroxide and potassium hydroxide.
The chemical mechanical polishing composition of the present invention optionally contain an abrasive. In some embodiments of the present invention, the chemical mechancial polishing composition contains 0 to 3 wt % abrasive. In some aspects of these embodiments, the chemical mechanical polishing composition contains ≦1 wt % abrasive. In some aspects of the present invention, the chemical mechanical polishing composition is abrasive-free.
Abrasive suitable for use with the present invention include, for example, abrasive having an average particle size of ≦500 nanometers (nm), preferably ≦100 nm, more preferably ≦70 nm. For purposes of this specification, particle size refers to the average particle size of the abrasive. In some embodiments, the abrasive is selected from colloidal abrasive, which can include additives, such as dispersants, surfactants, buffers, and biocides to improve the stability of the colloidal abrasive (e.g., Klebosol® colloidal silica from AZ Electronic Materials). In some embodiments, the abrasive is selected from fumed, precipitated and agglomerated abrasive. In some embodiments, the abrasive is selected from inorganic oxides, inorganic hydroxides, inorganic hydroxide oxides, metal borides, metal carbides, metal nitrides, polymer particles and mixtures comprising at least one of the foregoing. Suitable inorganic oxides include, for example, silica (SiO 2 ), alumina (Al 2 O 3 ), zirconia (ZrO 2 ), ceria (CeO 2 ), manganese oxide (MnO 2 ), titanium oxide (TiO 2 ) or combinations comprising at least one of the foregoing oxides. Suitable inorganic hydroxide oxides include, for example, aluminum hydroxide oxide (“boehmite”). Modified forms of these inorganic oxides, such as, organic polymer-coated inorganic oxide particles and inorganic coated particles can also be utilized if desired. Suitable metal carbides, boride and nitrides include, for example, silicon carbide, silicon nitride, silicon carbonitride (SiCN), boron carbide, tungsten carbide, zirconium carbide, aluminum boride, tantalum carbide, titanium carbide, or combinations comprising at least one of the foregoing metal carbides, boride and nitrides. Diamond may also be utilized as an abrasive if desired. Alternative abrasive also include polymeric particles, coated polymeric particles, and surfactant stabilized particles. The preferred abrasive, if utilized, is silica.
The chemical mechanical polishing composition and method of the present invention are particularly useful for chemical mechanical polishing of semiconductor wafers having copper interconnects. Notwithstanding, it is believed that the chemical mechanical polishing composition of the present invention are also suitable for polishing semiconductor wafers containing other conductive metal interconnects, such as aluminum, tungsten, platinum, palladium, gold, or iridium; a barrier or liner film, such as tantalum, tantalum nitride, titanium, or titanium nitride; and an underlying dielectric layer. For purposes of the specification, the term dielectric refers to a semi-conducting material of dielectric constant, k, which includes low-k and ultra-low k dielectric materials. The chemical mechanical polishing composition and method of the present invention are excellent for preventing erosion of multiple wafer constituents, for example, porous and nonporous low-k dielectrics, organic and inorganic low-k dielectrics, organic silicate glasses (OSG), fluorosilicate glass (FSG), carbon doped oxide (CDO), tetraethylorthosilicate (TEOS) and a silica derived from TEOS. The chemical mechanical polishing composition of the present invention can also be used for ECMP (Electrochemical Mechanical Polishing).
Some embodiments of the present invention will now be described in detail in the following Examples.
EXAMPLES
Example 1
Copolymer Synthesis
A 1:1 (weight ratio) copolymer of poly(ethylene glycol) methyl ether methacrylate and 1-vinylimidazole was prepared in a 5 liter closed batch reactor outfitted with a nitrogen purge, an agitator and a temperature control mechanism. The reactor was closed up and purged with nitrogen to provide a nitrogen atmosphere within the reactor. Deionized water (1,800 g) was then introduced to the reactor and the reactor contents were heated to 85° C. While maintaining the temperature of the reactor contents at 85° C., a monomer mixture containing deionized water (170.3 g); poly(ethylene glycol) methyl ether methacrylate (425.4 g) and 1-vinylimidazole (425.3 g) was added to the reactor gradually over 120 minutes. An initiator charge containing a mixture of deionized water (388.4 g); a substituted azonitrile compound (Vazo® available from Du Pont) (25.6 g) and ammonium hydroxide (63.9 g) was gradually added to the reactor over a period of 140 minutes coinciding with the monomer mixture feed. Following the initiator feed, the reactor contents were held at 85° C. for thirty minutes before adding a shot chase containing a mixture of deionized water (85.2 g); a substituted azonitrile compound (Vazo® available from Du Pont) (4.3 g); and ammonium hydroxide (21.3 g) to the reactor. The reactor contents were then held for 120 minutes at 85° C. before feeding an additional 425.1 g of deionized water to the reactor. The reactor contents were then allowed to cool to ˜60° C. The product copolymer was then isolated from the reactor contents.
Example 2
Polishing Tests
Two chemical mechanical polishing compositions were used in Example 2. Both chemical mechanical polishing compositions contained 0.30 wt % BTA; 0.22 wt % malic acid; 0.32 wt % carboxymethylcellulose (CMC); 1.3 wt % iminodiacetic acid (IDA); 2 wt % ammonium dihydrogenphosphate and 9 wt % hydrogen peroxide. The first chemical mechanical polishing composition (Composition 1) further contained 0.10 wt % of a 1:1 (weight basis) copolymer of poly(ethylene glycol) methyl ether methacrylate and 1-vinylimidazole having a weight average molecular weight, M w , of ˜36,000 prepared according to Example 1. The second chemical mechanical polishing composition (Composition 2) further contained 0.20 wt % of a 1:1 (weight basis) copolymer of poly(ethylene glycol) methyl ether methacrylate and 1-vinylimidazole having a weight average molecular weight, M w , of ˜36,000 prepared according to Example 1. The hydrogen peroxide was the last component added to the chemical mechanical polishing compositions before use. The noted component concentrations for the chemical mechanical polishing compositions are the point of use concentrations. The pH of the chemical mechanical polishing compositions was adjusted to 4.1 with nitric acid prior to the hydrogen peroxide addition. The pH following addition of the hydrogen peroxide was about 3.9.
Table 1 provides copper removal rate data determined with Composition 1. The copper removal rate experiments were performed using an Applied Materials, Inc. Mirra 200 mm polishing machine equipped with an ISRM detector system using an IC1010™ polyurethane polishing pad (commercially available from Rohm and Haas Electronic Materials CMP Inc.) under the down force condition provided in Table 1, a polishing solution flow rate of 160 ml/min, a table speed of 100 rpm and a carrier speed of 94 rpm. The copper blanket wafers used were electroplated and of 15K Å thickness (commercially available from Silyb). The copper removal rates were determined using a Jordan Valley JVX-5200T metrology tool. The copper removal experiments were each performed in duplicate. The data presented in Table 1 is the average for the duplicate experiments.
TABLE 1
Down Force (psi)
Copper Removal Rate (Å/min)
1
3862
1.5
5302
2
5850
2.5
6710
Table 2 provides copper removal rate and dishing performance using both Composition 1 and Composition 2 on 300 mm pattern wafers having copper interconnects and an MIT-754 pattern (commercially available from ATDF). An Applied Materials, Inc. Reflexion 300 mm polishing machine equipped with an ISRM detector system using an CUP4410 polyurethane polishing pad on platen 1 and a IC1010™ polyurethane polishing pad on platen 2 (both polishing pads are commercially available from Rohm and Haas Electronic Materials CMP Inc.) under downforce conditions (unless otherwise specified) of 1.5 psi (10.3 kPa), a polishing solution flow rate of 250 cc/min, a platen speed of 77 RPM, and a carrier speed of 71 RPM. A Diagrid® AD3BG-150855 diamond pad conditioner (commercially available from Kinik Company) was used to condition both polishing pads. The copper removal rates were determined using a Jordan Valley JVX®-5200T metrology tool. The dishing performances reported in Table 2 were determined using a Veeco® Dimension Vx 310 atomic force profiler (AFP).
TABLE 2
Copper
Removal
Center
Middle
Right Edge
Left Edge
Composition
Rate (Å/min)
(Å)
(Å)
(Å)
(Å)
1
4,600
300
330
480
430
2
5,569
540
420
500
440
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A method for chemical mechanical polishing of a semiconductor wafer containing a nonferrous metal is provided, comprising: providing a chemical mechanical polishing composition comprising 1 to 25 wt % of an oxidizer; 0.01 to 15 wt % of an inhibitor for the nonferrous metal; 0.005 to 5 wt % of a copolymer of poly(ethylene glycol) methyl ether(meth)acrylate and 1-vinylimidazole; and water; wherein the chemical mechanical polishing composition has an acidic pH; providing a chemical mechanical polishing pad; providing a semiconductor wafer containing the nonferrous metal; creating dynamic contact between the chemical mechanical polishing pad and the semiconductor wafer; and, dispensing the polishing solution at or near the interface between the chemical mechanical polishing pad and the semiconductor wafer.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a semiautomatic or fully automatic firearm, in particular in the form of a rifle or a pistol, containing a barrel whose rear barrel end is in the form of a cartridge chamber into which a projectile can in each case be inserted from the rear; a breech body which is arranged in a breech guide between the cartridge chamber and a rear wall such that it can move in the longitudinal direction between an open position, which releases the cartridge chamber in order to load a projectile, and a closed position which closes the cartridge chamber, wherein, in the closed position, the breech body closes the cartridge chamber at the rear and is used as an opposing bearing for the cartridge case.
[0002] The invention relates to a firearm with a locked breech and to firearms with an unlocked breech.
PRIOR ART
[0003] DE 31 30 761 A1 discloses an automatic handheld firearm, in particular an automatic pistol.
[0004] DE 10 2004 021 952 B3 discloses a self-loading handheld firearm.
[0005] FIG. 7 of German Laid-Open Specification 1 001 060 illustrates a firearm having a magnetic return system which has at least one permanent magnet in order to move a firing bolt back after a projectile has been fired.
[0006] Automatic firearms contain a plurality of moving parts, in particular a movable breech body. The breech body should have a high mass in order to withstand the recoil force of the projectile and the recoil forces of the hot gases from the projectile propellant charge. A high material mass makes the firearm heavy. For reasons associated with the capability of the parts to move and the relatively high mass of the breech, the aiming accuracy of automatic firearms is normally not as good as that of repeater rifles.
SUMMARY OF THE INVENTION
[0007] The aim of the invention is to solve the problem of improving the aiming accuracy (aiming precision) of automatic firearms, in a simple manner.
[0008] According to the invention, this problem is solved by a semiautomatic or fully automatic firearm, in particular in the form of a rifle or a pistol, comprising a barrel whose rear barrel end is in the form of a cartridge chamber into which a projectile can in each case be inserted from the rear. A breech body is arranged in a breech guide between the cartridge chamber and a rear wall such that it can move in the longitudinal direction between an open position, which releases the cartridge chamber in order to load a projectile, and a closed position closes the cartridge chamber, wherein, in the closed position, the breech body closes the cartridge chamber at the rear and is used as an opposing bearing for the cartridge case. At least one permanent magnet is provided such that, at least in the closed position and in the positions close to the closed position, its magnetic field forces the breech body to the closed position and the magnetic force of at least one permanent magnet simulates a higher mass of the breech body, which acts as an opposing bearing during the firing of a projectile.
[0009] According to the invention, a semiautomatic or fully automatic firearm is characterized in that at least one permanent magnet is provided such that, at least in the closed position and in the positions close to the closed position, its magnetic field forces the breech body to the closed position, such that the magnetic force of the at least one permanent magnet simulates a higher mass of the breech body, which acts as an opposing bearing during the firing of a projectile.
[0010] The invention advantageously increases the breech body force with which the breech body opposes the recoil forces of the projectile and the propellant-charge gases when a projectile is fired. The at least one permanent magnet simulates a higher mass of the breech body during the firing of a projectile, without the breech body having to be large and heavy in order to actually have the higher mass.
[0011] The invention increases the aiming accuracy of automatic firearms. The invention results in the aiming accuracy of automatic firearms being close to the aiming accuracy of repeater rifles.
[0012] The preferred field of application of the invention is, in particular but not exclusively, sporting weapons and firearms for sharpshooters.
[0013] The invention can be applied to all self-loading firearms.
[0014] For the purposes of the invention, a magnetic force can be produced not only between two or more permanent magnets but also between one or more permanent magnets on the one hand and a body which is composed of ferromagnetic or ferrimagnetic material, or contains such a material, on the other hand.
[0015] Instead of or in addition to the one and/or the other of the two above-mentioned options of magnetic attraction, it is also possible to force the breech body to its closed position by means of permanent magnets which magnetically repel one another.
[0016] According to one particular embodiment of the invention, the breech body and/or a body which forms the barrel and the cartridge chamber are/is themselves/itself magnetized as a permanent magnet or magnets such that it or they itself or themselves forms or form at least one of the at least one permanent magnets.
[0017] According to a further advantageous embodiment of the invention, in addition to the at least one permanent magnet, a spring can also be provided and is arranged such that it forces the breech body to the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be described in the following text with reference to the attached drawings and on the basis of a plurality of embodiments as examples. In the drawings:
[0019] FIG. 1 shows a cut-off longitudinal section of a firearm according to the invention, showing a breech body in the closed position;
[0020] FIG. 2 shows, schematically, the longitudinal section through the firearm shown in FIG. 1 , with the breech body being shown in its open position;
[0021] FIG. 3 shows, schematically, a side view of the barrel and of a breech body of the firearm shown in FIG. 1 , with a special arrangement of permanent magnets;
[0022] FIG. 4 shows a schematic side view of the barrel and of the breech body shown in FIG. 1 , with a further embodiment of an arrangement of permanent magnets;
[0023] FIG. 5 shows, schematically, a side view of the barrel and of the breech body shown in FIG. 1 , with yet another embodiment of an arrangement of permanent magnets;
[0024] FIG. 6 shows, schematically, a cut-off longitudinal section of a further embodiment of a firearm according to the invention;
[0025] FIG. 7 shows, schematically, a cut-off longitudinal section through yet another embodiment of a firearm according to the invention;
[0026] FIG. 8 shows, schematically, a cut-off longitudinal section through yet another embodiment of a firearm according to the invention;
[0027] FIG. 9 shows a front end view of the breech body shown in FIG. 1 , with an operating element added;
[0028] FIG. 10 shows, schematically, a side view of a further embodiment of a firearm according to the invention with the breech body shown in FIG. 9 in its closed position, in which mutually attracted permanent magnets are arranged aligned with one another in the barrel longitudinal direction;
[0029] FIG. 11 shows the same side view as in FIG. 10 , but with the breech body in a position rotated relative to the barrel, in which the permanent magnets which are provided for mutual attraction are arranged in the barrel longitudinal direction less or no longer aligned with one another,
[0030] FIG. 12 shows, schematically, a longitudinal section through a further embodiment of a firearm according to the invention, with a breech body being shown in the closed position,
[0031] FIG. 13 shows the firearm shown in FIG. 12 , with the breech body being shown in the open position, and
[0032] FIG. 14 shows, schematically, a longitudinal section through a further embodiment of a firearm according to the invention.
[0033] Of a firearm 2 according to the invention, FIGS. 1 and 2 show a barrel 4 and a breech body 6 . The rear section of the barrel 4 is in the form of a cartridge chamber 8 . The breech body 6 can be moved in the longitudinal direction of the barrel 4 , in a breech guide 10 , between the closed position as shown in FIG. 1 and the open position as shown in FIG. 2 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] In the closed position as shown in FIG. 1 , the breech body 6 forms an opposing bearing for absorbing the recoil of a projectile 12 in the cartridge chamber 8 when the propellant charge (not shown) of the projectile 12 is fired. When the propellant charge of the projectile 12 is fired, the cartridge 14 of the projectile 12 is driven through the bore 16 of the barrel 4 , while the cartridge case 18 is held in the cartridge chamber 8 by the breech body 6 against the explosion pressure of the propellant charge.
[0035] After firing, the breech body 6 is moved back to the open position as shown in FIG. 2 . During this process, the cartridge case 18 is ejected from the breech guide 10 , as a result of which a new projectile 12 can then automatically be inserted into the cartridge chamber 8 .
[0036] In order to fire the propellant charge of the projectile 12 , a firing bolt 20 strikes the center of the rear face of the projectile 12 .
[0037] In order to describe the invention, FIG. 1 shows the bore axis 22 of the barrel 4 and a center axis 24 (center line), which is aligned with this bore axis 22 , of the breech body 6 .
[0038] In the firearm 2 shown in FIG. 1 , the breech body 6 has, for example at its front end, at least one permanent magnet 26 ( 26 . 1 - 26 . n ), for example two permanent magnets 26 . 1 and 26 . 2 , of which one magnetic pole, for example the south pole “S” is in each case opposite, in the longitudinal direction of the barrel 4 , a dissimilar magnetic opposing pole, for example the north pole “N” of permanent magnets 28 ( 28 . 1 - 28 . n ), for example permanent magnets 28 . 1 and 28 . 2 , which are provided at the rear end 25 of the cartridge chamber 8 . In consequence, the mutually opposite permanent magnets 26 and 28 attract one another in the barrel longitudinal direction, and thus draw the breech body 6 to its closed position against the cartridge chamber 8 , and hold it in the closed position.
[0039] The permanent magnets 26 are preferably arranged on the front end face 23 of the breech body 6 or are integrated in this front end face 23 , for example by being arranged flush or recessed, or being formed by the breech body 6 itself.
[0040] The permanent magnets 28 are preferably arranged on the rear end face 25 of the cartridge chamber 8 or are integrated in this rear end face 25 , for example by being arranged flush or recessed.
[0041] In addition, a spring 30 can also be provided, for example a compression spring, which is clamped in the barrel longitudinal direction between the rear face 32 of the breech body 6 and a rear wall 34 , which is opposite it in the barrel longitudinal direction, of the breech guide 10 , thus forcing the breech body 6 to its closed position.
[0042] The permanent magnets 26 and 28 may have any desired shapes. For example, FIG. 3 shows a cartridge chamber 8 with the permanent magnets 28 . 1 , 28 . 2 and 28 . 3 in the form of bar magnets, as well as a breech body 6 with permanent magnets 26 . 1 , 26 . 2 and 26 . 3 in the form of bar magnets. The bar magnets extend in the barrel longitudinal direction. In this case, the south poles “S” of the permanent magnets 26 are opposite the north poles “N” of the permanent magnets 28 in the longitudinal direction of the barrel 4 .
[0043] FIG. 4 shows an arrangement similar to that in FIG. 3 , but with the permanent magnets 26 and 28 being arranged reversed, such that the north poles of the permanent magnets 26 are opposite the south poles of the permanent magnets 28 in the barrel longitudinal direction.
[0044] According to another embodiment of the invention, the permanent magnets 26 and 28 of the breech body 6 and of the cartridge chamber 8 are arranged such that south poles and north poles follow one another alternately in the circumferential direction around the center axis 24 .
[0045] In the embodiments shown in FIGS. 3 and 4 , the bar magnets 26 and 28 each extend in the barrel longitudinal direction.
[0046] In the embodiment shown in FIG. 5 , the bar magnets and 28 ( 26 . 1 , 26 . 2 , 28 . 1 , 28 . 2 ) each extend in the circumferential direction with respect to the bore axis 22 of the barrel 4 and with respect to the center axis 24 of the breech body 6 .
[0047] FIG. 6 shows an embodiment, similar to that shown in FIG. 1 , of a firearm 2 . 2 according to the invention. In this case, at least one, for example two permanent magnets 28 . 1 and 28 . 2 , are once again attached to the rear end 25 of the cartridge chamber 8 of the barrel 6 , as has been described above with reference to FIGS. 1 to 5 . However, the breech body 6 does not have any permanent magnets at its front end 23 axially opposite the cartridge chamber 8 but, at least at its front end 23 , is composed of ferromagnetic or ferrimagnetic material, or contains a material such as this there, which is attracted by the magnetic field of the permanent magnets 28 . 1 and 28 . 2 .
[0048] FIG. 7 shows one embodiment of a firearm 2 . 3 according to the invention, in which the breech body 6 has at least one permanent magnet 26 , for example two permanent magnets 26 . 1 and 26 . 2 , as has been described above with reference to FIGS. 1 to 5 , in a known manner on its front end 23 axially opposite the cartridge chamber 8 . However, that end 25 of the cartridge chamber 8 which faces backwards is not provided with a permanent magnet but is composed of ferromagnetic or ferrimagnetic material, or contains a material such as this, by which the breech body 6 is magnetically attracted by means of the magnetic field of the permanent magnets 26 in the barrel longitudinal direction. Instead of or in addition to this, an element which is adjacent to the cartridge chamber 8 and is arranged axially in a fixed position in the longitudinal direction of the barrel 4 , for example the front section of the breech guide 10 , could also be composed of ferromagnetic or ferrimagnetic material, or could have such a material.
[0049] FIG. 8 schematically illustrates one embodiment of a firearm 2 . 4 according to the invention, in which at least one, for example two or more, permanent magnets 36 ( 36 . 1 and 36 . 2 ) is or are mounted on the rear face 32 of the breech body 6 and may be formed in a corresponding manner to the permanent magnets in FIGS. 1 to 5 . At least one, preferably two or more, permanent magnets 38 , for example 38 . 1 and 38 . 2 is or are attached to the breech rear wall 34 such that its or their magnet poles is or are opposite similar magnet poles of the permanent magnets 36 of the breech body 6 in the barrel longitudinal direction, such that they repel one another and thus can force the breech body 6 in the direction from its open position to its closed position, and can hold it in the closed position by the permanent magnetic field.
[0050] FIG. 8 shows mutually opposite north poles of the permanent magnets 36 on the one hand and of the permanent magnets 38 on the other hand. However, according to another embodiment, the south poles “S” could be arranged axially opposite one another.
[0051] The permanent magnets 26 and 28 in the embodiments shown in FIGS. 1 to 7 are preferably arranged such that an axial air gap 40 remains between them and the opposing element which is magnetically attracted by them and may likewise be a permanent magnet or, in the stated manner, ferromagnetic or ferrimagnetic material, when the breech body 6 is in the closed position as illustrated in FIGS. 1 , 6 and 7 . For example, on its front face, the breech body 6 may have an axial projection 42 which, when the breech body 6 is in the closed position, can rest on the rear end surface 25 of the cartridge chamber 8 thus holding the mutually attracting permanent magnets 26 and 28 from FIGS. 1 to 5 at an axial distance, or, in the embodiment shown in FIGS. 6 , holding the at least one permanent magnet 28 of the barrel 4 at an axial distance from the front end surface 23 of the breech body 6 , or holding the at least one permanent magnet 26 of the breech body 6 as shown in FIG. 7 at an axial distance from the rear end surface 25 of the barrel 4 . According to another embodiment, the projection 42 can be axially supported on the projectile 12 . According to yet another embodiment, an axial projection could also be provided at the rear end of the barrel 6 or of the cartridge chamber 8 . According to yet another embodiment, the at least one permanent magnet 26 of the breech body 6 could be arranged set back (recessed) in the breech body 6 , and/or the at least one permanent magnet 28 could be arranged set back (recessed) axially in the cartridge chamber 8 .
[0052] FIG. 9 shows, schematically, a front end view of the breech body 6 shown in FIG. 1 , but also having an operating element 46 , for example a lever which projects radially. By way of example, four permanent magnets 26 . 1 , 26 . 2 , 26 . 3 and 26 . 4 of the at least one permanent magnet 26 are shown.
[0053] The operating element 46 of the breech body 6 is located behind a side aperture opening 50 , or projects into this aperture opening 50 , or through this aperture opening 50 , which is formed in the breech guide 10 . The breech body 6 can thus be rotated relative to the barrel 4 by means of the operating element 46 about the center axis 24 between a magnetically active position, in which the permanent magnets 26 and 28 which magnetically attract one another are arranged opposite one another, essentially completely aligned with one another, in the barrel longitudinal direction, and a magnetically inactive position, such that, in the magnetically inactive position, the at least one permanent magnet 26 of the breech body 6 is positioned rotationally offset with respect to the at least one permanent magnet 28 of the barrel 4 , as a result of which the magnetic attraction force is considerably reduced in the magnetically inactive position, which is shown in FIG. 11 , or is inactive in comparison to the magnetically active position which is shown in FIGS. 10 and 1 to 5 . This results in a strong magnetic opposing force for firing of a cartridge 14 , but a considerably reduced, or no magnetic attraction force for the return movement or opening of the breech body 6 , for the ejection of the cartridge case 18 and for the insertion of a new projectile 12 . This makes it considerably easier for the breech body 6 to move back, particularly during the initial movement from the closed position.
[0054] The at least one permanent magnet of the breech body 6 , for example the permanent magnets 26 ( 26 . 1 . . . 26 . n ) and 36 ( 36 . 1 . . . 36 . n ) may, in all embodiments of the invention, be an element added to the breech body 6 or may be formed by the breech body 6 itself, in that the breech body is composed at least partially of material which can be magnetized, and this material which can be magnetized is magnetized as a permanent magnet.
[0055] In all of the embodiments described above, in which at least one permanent magnet is arranged on or in the cartridge chamber 8 , for example the permanent magnets 28 ( 28 . 1 . . . 28 . n ) in FIGS. 1 to 6 and FIGS. 10 and 11 , which magnetically draw the breech body 6 to its closed position, these permanent magnets could also be provided on another element which forms an integral part with the cartridge chamber 8 , is attached to the cartridge chamber 8 or can be positioned axially in a fixed position in the longitudinal direction of the barrel 4 in some other manner, such that it cannot be moved in the longitudinal direction of the barrel 4 while a shot is being fired. By way of example, one such element may also be the breech guide 10 .
[0056] The rear wall 34 may be a part of the breech guide 10 or an additional part.
[0057] FIGS. 12 and 13 show a firearm 2 . 5 according to the invention, in which a permanent magnet 56 of the breech body 6 is arranged, in the longitudinal direction of the barrel 4 , axially between a permanent magnet 58 which magnetically attracts it and is arranged axially in a fixed position in the longitudinal direction of the barrel 4 , for example two permanent magnets 58 . 1 and 58 . 2 , and at least one further permanent magnet 68 , which magnetically repels it, for example 68 . 1 and 68 . 2 , with the latter being arranged axially in a fixed position in the longitudinal direction of the barrel 4 . For example, the mutually repelling permanent magnets 56 and 68 are arranged with their south poles “S” axially opposite one another, and the at least one permanent magnet 58 , which magnetically attracts the permanent magnet 56 of the breech body 6 , is, for example, arranged with its north pole axially opposite the south pole of the permanent magnet 56 .
[0058] The permanent magnet 68 which repels the permanent magnet 56 of the breech body 6 is preferably arranged in the rear wall 34 or on a rear section of the breech guide 10 . The permanent magnet 58 which magnetically attracts the permanent magnet 56 of the breech body 6 can be provided in the described manner on or in the cartridge chamber 8 or, corresponding to FIGS. 12 and 13 , on or in a front section of the breech guide 10 .
[0059] The at least one permanent magnet 56 of the breech body 6 can be arranged on or within the breech body 6 , or may be formed by the breech body 6 itself, or may be formed corresponding to FIGS. 12 and 13 on a radial annular collar of the breech body 6 . The permanent magnets 58 and 68 which magnetically attract and magnetically repel the at least one permanent magnet 56 of the breech body 6 and are axially in a fixed position are arranged at such a long distance 70 from one another in the longitudinal direction of the barrel 4 that the breech body 6 can be moved through a movement distance 72 within this distance 70 in the longitudinal direction of the barrel 4 , with this movement distance 72 being that which is required in order to move the breech body between its closed position in FIG. 12 and its open position in FIG. 13 .
[0060] FIG. 14 shows, schematically, a longitudinal section through a further embodiment of a firearm 2 . 6 according to the invention, in which the breech body 6 has, at its front end, at least one permanent magnet pole, for example a magnetic north pole “N”, and, at the rear end, a dissimilar permanent magnet pole, for example a magnetic south pole “S”. The two permanent magnet poles may, for example, be formed by two permanent magnets 26 and 56 or by a single permanent magnet, for example by the breech body 6 itself, if it is in the form of a permanent magnet.
[0061] A dissimilar permanent magnet pole, for example a south pole “S”, of at least one permanent magnet 28 is located opposite the front permanent magnet pole, for example a north pole “N”, of the breech body 6 , and is provided on the cartridge chamber 8 (or on another element which is axially in a fixed position relative to it).
[0062] A similar permanent magnet pole, for example a south pole “S”, of at least one permanent magnet 68 is located opposite the rear permanent magnet pole, for example a south pole “S”, of the breech body 6 in the longitudinal direction of the barrel 4 and is arranged axially in a fixed position in the barrel longitudinal direction, for example on or in the rear wall 34 , or is formed by means of the rear wall 34 , and/or is connected to the breech guide 10 .
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Semiautomatic or fully automatic firearm, in particular in the form of a rifle or a pistol, containing a barrel whose rear barrel end is in the form of a cartridge chamber into which a projectile can in each case be inserted from the rear; a breech body which is arranged in a breech guide between the cartridge chamber and a rear wall such that it can move in the longitudinal direction between an open position, which releases the cartridge chamber in order to load a projectile, and a closed position which closes the cartridge chamber, wherein, in the closed position, the breech body closes the cartridge chamber at the rear and is used as an opposing bearing for the cartridge case; characterized in that at least one permanent magnet is provided such that, at least in the closed position and in the positions close to the closed position, its magnetic field forces the breech body to the closed position, such that the magnetic force of the at least one permanent magnet simulates a higher mass of the breech body, which acts as an opposing bearing during the firing of a projectile.
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BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to tension members such as those used in elevator systems for suspension and/or driving of the elevator car and/or counterweight.
[0002] Conventional elevator systems use rope formed from steel wires as a lifting tension load bearing member. Other systems utilize a lifting belt formed from a number of steel cords, formed from steel wires, retained in an elastomeric jacket. The cords act as the load supporting tension member, while the elastomeric jacket holds the cords in a stable position relative to each other, and provides a frictional load path to provide traction for driving the belt.
[0003] Still other systems utilize woven belts, in which yarns or other non-metallic fibers are woven together with the steel cords to retain the cords. The woven belt is also saturated or coated with an elastomeric binder. This is done to produce a selected amount of traction between the belt and a traction sheave that drives the belt, while reducing noise that sometimes results from the use of elastomeric belts. The steel cords in the woven belt are the primary load bearing tension members, the yarns and the binder material act to keep the cords in place and provide a traction surface. The use of yarn materials also expands the physical properties of the construction beyond what is possible from thermoplastic or extrudable rubber jacket materials. These properties include, but are not limited to, tensile strength, friction properties and flammability. In the woven belts, the yarns are oriented at angular orientations of 0 degrees and 90 degrees relative to the steel cords, and the belt is assembled by a weaving process on a loom. The weaving process is inefficient and time consuming.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one embodiment, a belt for suspending and/or driving an elevator car includes a plurality of tension elements extending along a length of the belt and a plurality of belt fibers transverse to the plurality of tension elements and interlaced therewith. The belt fibers define at least one traction surface of the belt. An edge fiber is located at a lateral end of the belt and is secured to the plurality of belt fibers to secure the belt fibers in a selected position.
[0005] Alternatively or additionally, in this or other embodiments, the edge fiber includes adhesive to secure the edge fiber to the plurality of belt fibers.
[0006] Alternatively or additionally, in this or other embodiments, the edge fiber includes a thermally-activated material to secure the edge fiber to the plurality of belt fibers.
[0007] Alternatively or additionally, in this or other embodiments, the edge fiber extends parallel to the plurality of tension elements.
[0008] Alternatively or additionally, in this or other embodiments, the plurality of belt fibers is transverse to the plurality of tension elements at a non-perpendicular angle.
[0009] Alternatively or additionally, in this or other embodiments, the angle is forty-five degrees.
[0010] Alternatively or additionally, in this or other embodiments, the tension elements are formed from a first material and the belt fibers are formed from a second, different material.
[0011] Alternatively or additionally, in this or other embodiments, the tension elements are formed from a metallic material and the belt fibers are formed from a non-metallic material.
[0012] Alternatively or additionally, in this or other embodiments, the belt fibers comprise a thermoplastic material.
[0013] Alternatively or additionally, in this or other embodiments, the belt fibers include thermoplastic filaments.
[0014] Alternatively or additionally, in this or other embodiments, the belt fibers are at least partially coated with an elastomeric material.
[0015] In another embodiment, a method of forming a belt for suspending and/or driving an elevator car includes arranging a plurality of tension elements along a length of the belt, defining a length of the belt and braiding a plurality of belt fibers together with the plurality of tension elements to form a braided structure. The plurality of belt fibers extends transverse to the plurality of tension elements. An edge fiber is braided into the plurality of belt fibers at a lateral side of the braided structure, and the edge fiber is secured to the plurality of belt fibers to retain the weave fibers in a selected position.
[0016] Alternatively or additionally, in this or other embodiments, the edge fiber is heated to secure the edge fiber to the plurality of belt fibers.
[0017] Alternatively or additionally, in this or other embodiments, an edge fiber is braided into the plurality of belt fibers at each lateral side of the braided structure.
[0018] Alternatively or additionally, in this or other embodiments, the edge fiber extends parallel to the plurality of tension elements.
[0019] Alternatively or additionally, in this or other embodiments, the plurality of belt fibers is transverse to the plurality of tension elements at a non-perpendicular angle.
[0020] Alternatively or additionally, in this or other embodiments, the angle is forty-five degrees.
[0021] Alternatively or additionally, in this or other embodiments, a band of selvage fibers are braided into the braided structure between adjacent tension elements of the plurality of tension elements.
[0022] Alternatively or additionally, in this or other embodiments, the selvage fibers are secured to the plurality of belt fibers.
[0023] Alternatively or additionally, in this or other embodiments, the braided structure is separated into two braided structures at the band of selvage fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1A is a schematic of an exemplary elevator system having a 1:1 roping arrangement;
[0025] FIG. 1B is a schematic of another exemplary elevator system having a different roping arrangement;
[0026] FIG. 1C is a schematic of another exemplary elevator system having a cantilevered arrangement;
[0027] FIG. 2 is a plane view of an embodiment of an elevator belt;
[0028] FIG. 3 is a cross-sectional view of an embodiment of an elevator belt;
[0029] FIG. 4 is a plane view of another embodiment of an elevator belt;
[0030] FIG. 5 is a plane view of yet another embodiment of an elevator belt;
[0031] FIG. 6 is a plane view of still another embodiment of an elevator belt;
[0032] The detailed description explains the invention, together with advantages and features, by way of examples with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Shown in FIGS. 1A, 1B and 1C are schematics of exemplary traction elevator systems 10 . Features of the elevator system 10 that are not required for an understanding of the present invention (such as the guide rails, safeties, etc.) are not discussed herein. The elevator system 10 includes an elevator car 12 operatively suspended or supported in a hoistway 14 with one or more belts 16 . The one or more belts 16 interact with one or more sheaves 18 to be routed around various components of the elevator system 10 . The one or more belts 16 could also be connected to a counterweight 22 , which is used to help balance the elevator system 10 and reduce the difference in belt tension on both sides of the traction sheave during operation.
[0034] The sheaves 18 each have a diameter 20 , which may be the same or different than the diameters of the other sheaves 18 in the elevator system 10 . At least one of the sheaves could be a traction sheave 52 . The traction sheave 52 is driven by a machine 50 . Movement of drive sheave by the machine 50 drives, moves and/or propels (through traction) the one or more belts 16 that are routed around the traction sheave 52 .
[0035] At least one of the sheaves 18 could be a diverter, deflector or idler sheave. Diverter, deflector or idler sheaves are not driven by a machine 50 , but help guide the one or more belts 16 around the various components of the elevator system 10 .
[0036] In some embodiments, the elevator system 10 could use two or more belts 16 for suspending and/or driving the elevator car 12 . In addition, the elevator system 10 could have various configurations such that either both sides of the one or more belts 16 engage the one or more sheaves 18 (such as shown in the exemplary elevator systems in FIG. 1A, 1B or 1C ) or only one side of the one or more belts 16 engages the one or more sheaves 18 .
[0037] FIG. 1A provides a 1:1 roping arrangement in which the one or more belts 16 terminate at the car 12 and counterweight 22 . FIGS. 1B and 1C provide different roping arrangements. Specifically, FIGS. 1B and 1C show that the car 12 and/or the counterweight 22 can have one or more sheaves 18 thereon engaging the one or more belts 16 and the one or more belts 16 can terminate elsewhere, typically at a structure within the hoistway 14 (such as for a machineroomless elevator system) or within the machine room (for elevator systems utilizing a machine room. The number of sheaves 18 used in the arrangement determines the specific roping ratio (e.g. the 2:1 roping ratio shown in FIGS. 1B and 1C or a different ratio). FIG. 1C also provides a so-called rucksack or cantilevered type elevator. The present invention could also be used on elevator systems other than the exemplary types shown in FIGS. 1A, 1B and 1C .
[0038] The belts 16 are constructed to have sufficient flexibility when passing over the one or more sheaves 18 to provide low bending stresses, meet belt life requirements and have smooth operation, while being sufficiently strong to be capable of meeting strength requirements for suspending and/or driving the elevator car 12 .
[0039] FIG. 2 provides a schematic of an exemplary belt 16 construction or design. The belt 16 includes a plurality of tension elements 32 . As shown in FIG. 3 , in some embodiments, the tension elements are cords formed from a plurality of steel wires 36 , which may be arranged into strands 38 . Referring again to FIG. 2 , the tension elements 32 are arranged generally parallel to each other and extend in a longitudinal direction that establishes a length of the belt 16 . A plurality of belt fibers 40 that are braided together with the tension elements 32 into a fabric that substantially retains the tension elements 32 has a selected orientation relative to each other. The phrase “substantially retains” means that belt fibers 40 sufficiently engage the tension elements 32 such that the tension elements 32 to not pull out of, or move relative to, the belt fibers 40 in use of the belt 16 .
[0040] Referring again to FIG. 3 , the belt 16 includes a traction surface 42 on at least one side of the belt 16 , and is defined by the belt fibers 40 . Having the traction surface 42 defined by the belt fibers 40 includes the belt fibers 40 being exposed at the traction surface 42 , a coating over the belt fibers 40 having a surface contour defined by the presence of the belt fibers 40 , or a combination of these.
[0041] The tension elements 32 are the primary load bearing structure of the elevator belt 16 . In some embodiments, the belt fibers 40 do not support the weight of the elevator car 12 or counterweight 22 . Nevertheless, the belt fibers 40 do form part of the load path. The belt fibers 40 transmit the traction forces between the traction sheave 52 and the belt 16 to the tension elements 32 . Such traction force transmission in some examples is direct (e.g. when the belt fibers 40 are exposed at the traction surface 42 ) or indirect (e.g. when the belt fibers 40 are coated and the coating establishes the exterior of the traction surface 42 ).
[0042] The belt fibers 40 are arranged in a pattern relative to the tension elements 32 so that a spacing between the traction surface 42 and the tension elements 32 prevents the tension elements 32 from contacting a component that the traction surface 42 engages. For example, the tension elements 32 will not contact a surface on the traction sheave 52 as the belt 16 wraps at least partially around the traction sheave 52 . The size of the belt fibers 40 , the material of the belt fibers 40 , the pattern of the belt fibers 40 or a combination of these is selected to ensure the desired spacing between the tension elements 32 and the traction surface 42 so that the tension elements 32 are protected from direct engagement with a component such as the traction sheave 52 . In one embodiment, a coating over the belt fibers 40 protects the weave fibers 40 and therefore ensures that the tension elements 32 are sufficiently spaced from the traction surface 42 so that the tension elements 32 will not directly engage or come into contact with the traction sheave 52 or another sheave 18 of the elevator system.
[0043] In an embodiment, the tension elements 32 are formed from a first material, such as drawn steel, and the belt fibers 40 are formed from a second, different material and have a much smaller thickness and/or cross-sectional dimension compared to the tension elements 32 . The belt fibers 40 may be formed from, for example, a nonmetallic material such as a polymer. In some embodiment, the belt fibers 40 include a thermoplastic material that is useful for establishing the traction surface 42 . One embodiment includes forming the belt fibers 40 , then coating the belt fibers 40 with the elastomeric material. In another embodiment, the belt fibers 40 are formed, braided to the tension elements 32 , then selectively coated with the elastomeric material. In still another embodiment, the belt fibers 40 are formed from a plurality of filaments, with at least one of the filaments including the thermoplastic material.
[0044] The belt fibers 40 are oriented at a non-perpendicular angle to the tension elements 32 , for example, at +/−60 degrees or +/−45 degrees relative to the tension elements. Further, the belt fibers 40 may include first belt fibers 40 a orientated at a first angle relative to the tension elements 32 and second belt fibers 40 b oriented at a second angle relative to the tension elements 32 . Braiding with the belt fibers 40 oriented at angles other than 0 and 90 degrees relative to the tension elements 32 provides a tightening effect when as the belt 16 is formed, as well as when the belt 16 is initially put into service and a load is applied to it. The tightening improves dimensional stability of the belt 16 as well as greater control over traction of the belt 16 during operation. Thermoplastic, elastomeric, adhesive and/or thermally-activated materials may be included in the belt 16 to improve dimensional and physical properties of the belt 16 .
[0045] Referring now to FIG. 4 , in addition to the belt fibers 40 and the tension elements 32 , the belt 16 includes edge fibers 46 extending along the length of the belt 16 substantially parallel to the tension elements 32 . The edge fibers 46 may be formed from an adhesive or thermally-activated material, which when set, secures the positions of the belt fibers 40 , preventing the belt 16 from fraying or unraveling at the edges. In some embodiments, the edge fibers 46 may be mechanically closed around the belt fibers 40 by, for example, tying, to secure the edge fiber 46 and belt fiber 40 position.
[0046] Referring now to FIGS. 5 and 6 , the braiding arrangement of the belt fibers 40 allows for the simultaneous manufacturing of multiple belts 16 . Tension elements 32 for two or more belts 16 are arranged side-by-side, along with edge fibers 46 at the edges, and a band of selvage fibers 48 , or alternatively, additional edge fibers 46 between adjacent tension elements 32 . The belt fibers 40 a and 40 b are braided through the edge fibers 46 , tension elements 32 and selvage fibers 48 defining a single braided structure. The edge fibers 46 and selvage fibers 48 , if needed, are activated by, for example, application of heat, to secure the belt fibers 40 a and 40 b in place. Finally, the braided structure is separated into two or more belts 16 , as shown in FIG. 6 , by cutting or otherwise separating the structure between the selvage fibers 48 . Manufacturing of more than one belt 16 at a time utilizing this method increases efficiency of fabrication and reduces material waste in fabrication. While the embodiment illustrated produces two belts 16 simultaneously, one skilled in the art will recognize that such method may be used to fabricate 3, 4 or more belts 16 simultaneously.
[0047] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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A belt for suspending and/or driving an elevator car includes a plurality of tension elements extending along a length of the belt and a plurality of belt fibers transverse to the plurality of tension elements and interlaced therewith. The belt fibers define at least one traction surface of the belt. An edge fiber is located at a lateral end of the belt transverse to and secured to the plurality of belt fibers to secure the belt fibers in a selected position.
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BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of integrated circuits. Specifically, a system for heating semiconductor substrates in a controlled pressure and temperature environment is disclosed.
The manufacture of integrated circuits, such as metal oxide semiconductors (MOS), requires rapid thermal processing of semiconductor wafers in a controlled pressure environment, such as vacuum. For instance, in the process of forming MOS transistors, the gate oxide layer is typically formed by thermal oxidation of a silicon substrate in a substantially pure oxygen atmosphere. However, in certain applications such as MOS ULSI circuits, the gate oxide layers can exhibit undesirable characteristics, such as relatively high defect densities and charge trapping, along with relatively low reliability and resistance problems due to hot carrier effects.
It is known that the gate dielectric characteristics of MOS transistors can be improved using a sequence of rapid thermal processing (RTP) of the silicon substrate. These processing steps include: (1) creating an oxynitride growth with nitric oxide (NO); (2) applying silicon nitride (SiN) with a chemical vaport deposition (CVD) process; (3) annealing with ammonia (NH 3 ); and (4) annealing with N 2 O. The various RTP processing steps are conducted generally in a vacuum with a controlled temperature. An RTP oven is partitioned with quartz windows defining a central vacuum chamber that holds a wafer to be heated by multiple arrays of radiant heating lamps. The quartz windows separate the wafers from heating lamps and other sources of contaminants during the heating process. The edges of the quartz windows are sealed with the chamber walls to form an air-tight chamber enclosure. When a vacuum is drawn in the chamber, an atmospheric force between two and four tons is produced against the quartz windows. The quartz windows are thick enough to withstand this force, and are generally at least about 25 mm to 35 mm thick. Thinner quartz windows, generally at least about 3 mm to 6 mm thick, are used only for chambers that operate at atmospheric pressures.
The quartz window isolation chamber structure, while maintaining the inner chamber environment clean of contaminants, introduces a large thermal mass between the heating source (lamps) and the wafer within the chamber, making heating less efficient and wafer temperature control more difficult. The additional thermal mass makes it difficult to maintain process repeatability and quality control. The quartz windows, due to their thickness, are subject to breakage, and add significant cost to the RTP apparatus. Accordingly, a system for rapid thermal processing which avoids the complications, expense, and repeatability problems created by quartz window-based ovens would be desirable.
Moreover, efforts to increase throughput for semiconductor wafer RTP processing have yielded certain alternatives other than lamp-based heating. Mattson Technology offers an ASPEN II RTP system that processes two wafers in a single process chamber using susceptor-based heating. U.S. Pat. No. 6,133,550 discloses a method for RTP processing wafers by rapidly inserting and removing them from a furnace. Increasing wafer size and increasing stresses on larger and larger chamber windows for chambers to accommodate larger wafers have limited the potential for increasing throughput for lamp-based RTP systems by processing multiple wafers in a chamber. Accordingly, a system for lamp-based rapid thermal processing that permits increased wafer throughput would also be desirable.
SUMMARY OF THE INVENTION
The rapid thermal processing (RTP) system according to the invention provides a controlled pressure and temperature environment for processing substrates, such as semiconductor wafers and integrated circuits. The apparatus includes a heating chamber and an array of heat lamps that generate radiant heat for maintaining the temperature of a semiconductor wafer held within the chamber at a selected value or range of values according to a desired heating recipe. Each heat lamp includes a bulb, and at least such bulb is surrounded by an optically transparent enclosure that isolates the bulb from the interior of the chamber and the wafer therein. Preferably, the optically transparent enclosure is formed from quartz and has a surface completely or substantially transparent to the radiant heat energy emitted by the bulb. By isolating the chamber interior and the wafer therein from the bulb and associated components of the heating lamp, the optically transparent enclosure helps prevent contaminants from the heating lamps from entering the chamber or being deposited on a semiconductor wafer in the chamber.
In another aspect of the invention, improved temperature control is realized by using heat lamps with bulbs having a reflector surface disposed over at least a portion of the bulb surface or disposed over at least a portion of the optically transparent enclosure. The reflectors help to control and direct radiation from the lamps to the surface of a semiconductor wafer under process. Alternatively, the reflector surface may be found on the wall of the chamber, particularly within a cavity in the chamber wall with a concavely-shaped or parabolic-shaped inner surface. When the heat lamps are positioned within the cavity, the reflector surface on the cavity wall helps to control and direct radiation from the lamps to the surface of a semiconductor wafer under process.
In a preferred embodiment, the optically transparent enclosure surrounding the bulb is formed into a lens structure that concentrates the radiant heat emitted from the bulb onto the semiconductor wafer surface. The lens structure may be formed as a convexly-curved cover over the opening to the cavity in the chamber wall when the heat lamp is held within such cavity. Alternatively, the lens structure may be formed as a sold block or piece of optically transparent material, such as quartz, with an open inner core portion to house a heat lamp, wherein one side surface of said block is formed into a convexly-shaped or concavely-shaped lens to direct or control radiant heat energy emitted from the bulb toward a semiconductor wafer being processed.
In yet another embodiment of the invention, an optically transparent liner is interposed between an array of the enclosed heating lamps and the single wafer or multiple wafers in the processing chamber enclosure. The optically transparent liner is provided in addition to the optically transparent enclosures surrounding the bulbs, and further isolates the bulbs from the wafer to further restrict contaminants from reaching the wafer surface. The optically transparent liner differs from the quartz windows of the prior art because it is not sealed to the chamber sidewalls, and may therefore be formed as a thinner piece because it does not need to withstand great pressure differentials when a vacuum is drawn in the chamber. If the optically transparent liner is sealed to the chamber sidewalls, a series of valves are provided in addition to the pump to equalize the pressures of each side of the liner, thereby preventing damaging forces that otherwise would be caused by pressure differentials. Alternatively, to avoid undue stresses, a series of multiple optically transparent liners with smaller surface areas may also be used in combination with the bulbs.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments of the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, without departing from the invention. Accordingly, the description is to be regarded as illustrative in nature and not as restrictive.
DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a conventional prior art rapid thermal processing system providing a controlled temperature and pressure environment for semiconductor wafers;
FIG. 2 is a section view of a rapid thermal processing system in accordance with a preferred embodiment of the invention;
FIG. 2A is a partial cross-sectional view in side elevation taken along line 2 A to 2 A of FIG. 2 .
FIG. 3 is a section view of an alternate embodiment of the rapid thermal processing system;
FIG. 4 is a section view of a heat lamp for directing radiant energy to a semiconductor wafer within the rapid thermal processing system;
FIG. 5 is a section view of an alternate embodiment of the heat lamp for directing radiant energy to a semiconductor wafer within the rapid thermal processing system;
FIG. 6 is a section view of a heat lamp having a reflector for directing radiant energy;
FIG. 7 is a section view of a heat lamp having another arrangement for directing radiant energy to a semiconductor wafer in a rapid thermal processing system.
FIG. 8 is a section view of a heat lamp with yet another arrangement of a reflector for directing radiant energy to a semiconductor wafer in a rapid thermal processing system;
FIG. 9 is a cross-section view of an array of heat lamps embedded within the wall of a rapid thermal processing system chamber;
FIG. 10A is a section view of the heat lamp and quartz enclosure supported on the chamber wall of a rapid thermal processing system;
FIG. 10B is a section view of the quartz enclosed heat lamp in an alternate arrangement partially embedded in the chamber wall;
FIG. 10C is a section view of the quartz enclosed heat lamp in yet another alternate arrangement completely embedded in a cavity in the chamber wall;
FIG. 10D is a section view of the heat lamp embedded within a cavity in the chamber wall and with a quartz window covering an opening to the cavity;
FIG. 10E is a section view of the heat lamp embedded in the chamber wall and having a lens for controlling dispersion of radiant energy emitted from the lamp;
FIG. 10F is a section view of multiple lamps within a single quartz enclosure supported on the chamber wall;
FIG. 11A is a section view of a point lamp enclosed by a quartz lens;
FIG. 11B is a section view of a lamp embedded in a light pipe and enclosed by a quartz lens;
FIG. 11C is a section view of a lamp within a light pipe and having a lens at the distal end of the light pipe;
FIG. 11D is a section view of an alternate arrangement with a lamp embedded in a cavity in the chamber wall and surrounded by a quartz lens;
FIG. 12 is a section view of a heat lamp in a diverging quartz lens;
FIG. 13 is a section view of an alternate embodiment having a lamp within a quartz enclosure surrounded by a cooling source and embedded in a cavity in the chamber wall;
FIG. 14 is a bottom plan view of the chamber wall of an alternate rapid thermal processing system according to the invention showing point lamps held within channels in the chamber wall, wherein said channels are covered with optically transparent enclosures;
FIG. 15 is a section view of another alternate rapid thermal processing system in accordance with a preferred embodiment of the invention, showing two wafers held within the chamber; and
FIG. 16 is a section view of yet another alternate rapid thermal processing system in accordance with a preferred embodiment of the invention, showing a series of optically transparent liners in combination with a series of point-source heating lamps.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the prior art, FIG. 1 is a longitudinal section view of an apparatus 10 for performing rapid thermal processing (RTP) of a semiconductor wafer 7 . The apparatus 10 provides a housing 12 defining a central chamber 11 in which a wafer is placed for processing. Door slot 26 at a first end of vacuum chamber 11 permits the wafer 7 to be loaded into the chamber 11 and located on supporting pins 25 on the rotor 23 . The rotor 23 is supported for rotation on a pin 24 fixed to a boss 21 a extending from quartz window 21 through an opening in quartz pad 27 .
Quartz window 21 forms the lower boundary of the vacuum chamber 11 , and is sealed with respect to the remaining chamber components by seals 28 . The upper boundary of the chamber 11 is formed with a quartz window 20 . Quartz windows 20 , 21 are optically transparent and permit radiant heat energy to pass into the chamber 11 . Processing gases such as nitric oxide (NO), ammonia (NH 3 ), or N 2 O are introduced into the chamber 11 during the wafer processing through an opening 13 at a second end of the chamber 11 .
The radiant heat source for the apparatus 10 comprises first and second substantially parallel lamp arrays 17 and 18 located within the housing 12 , but outside of the chamber 11 , and supported by the inner walls of the apparatus 10 . Additional radiant heat is provided by longitudinal side lamps 14 having reflectors 15 supported by the wall of the apparatus 10 . A vacuum port (not shown) permits a vacuum to be drawn within the chamber 11 , resulting in significant atmospheric forces acting against the quartz windows 20 and 21 .
The quartz windows 20 and 21 have a sufficient thickness with adequate mechanical strength to isolate the chamber from any external contamination. They are usually at least 3 mm to 6 mm thick. As the demands for larger semiconductor wafer sizes and higher wafer throughput in the rapid thermal processing system increase, the cross sectional area increases. In addition, low pressure process chambers are required to be compatible with vacuum load-locks and wafer transfer modules to enhance throughput. The thickness of quartz windows 20 and 21 required for low pressure RTP apparatus will need to be significantly increased to meet these requirements. When a vacuum is drawn in the RTP chamber, an atmospheric force of between two and four tons is produced against the quartz windows. These windows must be thick enough to withstand this force, and are generally from 25 mm to 35 mm thick. As the thickness of the quartz windows increases, the distance between the arrays of heating lamps 17 , 18 and the chamber 11 also increases. Moreover, the thicker windows provide a large thermal mass, making control over the wafer temperature more difficult. Therefore, the present inventors sought to overcome these disadvantages.
In accordance with one preferred embodiment of the invention, the quartz windows 20 , 21 of conventional RTP apparatus (FIG. 1) may be eliminated. Referring now to FIG. 2, the RTP apparatus 60 of the first embodiment of the invention has a chamber 62 that includes wafer holders 65 to support the semiconductor wafer 64 during thermal processing. Wafer 64 is loaded into the chamber 62 through a door slot or opening 67 . Optically transparent liners 66 and 68 , which may be quartz, do not form a pressure sealing surface with the chamber 62 , but are supported within the chamber 62 so that the pressure is equalized on each side of the liners 66 and 68 . Thus, the liners 66 and 68 may be thinner, and have less thermal mass, than the conventional chamber quartz windows that must sustain large atmospheric pressure differentials but still assist in maintaining the wafers free of contamination. The liners have a thickness preferably of about 0.25 mm to 2.0 mm, most preferably of about 1.0 to 2.0 mm, and may be formed of silicon carbide (SiC) or other ceramic materials that are optically transparent and able to withstand typical rapid thermal processing temperatures, that can exceed 1000° C.
In the embodiment of FIG. 2, first and second arrays of light sources, such as tungsten halogen heating lamps or Xenon arc lamps, are provided along the top and bottom of the chamber 62 , i.e., above and below the wafer supports 65 . The arrays of light sources along the top and bottom of the chamber 62 supply direct radiant heat to the wafer 64 as the wafer is held on the wafer supports 65 . Each light source includes a linear lamp 70 , 72 within an optically transparent enclosure (such as a quartz tube) 74 , 76 on the top and bottom of chamber 62 . The quartz tubes 74 , 76 individually surround each lamp 70 , 72 , and are sealed to the sidewalls of chamber 62 with seals 78 , 80 , thus maintaining both the area surrounding the quartz tubes 74 , 76 and the remaining portion of the chamber 62 at the same pressure, preferably under vacuum. The top and bottom walls 91 , 93 of the chamber 62 may be coated with a reflective coating 69 , such as metallic gold or other infrared reflective coatings, such as TiO 2 and Al 2 O 3 . As best seen in FIG. 2A, the lamps 70 , 72 preferably are disposed in parallel relation, with each enclosed lamp spaced apart only slightly from an adjacent enclosed lamp, and spaced apart from the top wall and bottom wall, respectively, of the chamber and reflective coating 69 . While each of the arrays are shown in parallel, it is of course possible to have the arrays oriented in a perpendicular or other non-parallel relationship. In addition, a first parallel array adjacent to the top wall 91 of the chamber may be parallel to a second parallel array adjacent to the bottom wall 93 of the chamber. Nevertheless, the lamps of the second parallel array may be arranged transversely to the lamps of the first parallel array.
Individual cooling channels having an inlet 82 and an outlet 84 circulate cooling fluid, such as a liquid like water or a cooling oil, or a gas with suitable thermal conductivity like air, or a mixture of air and helium or hydrogen, through each quartz tube 74 , 76 to cool the lamps 70 , 72 . The cooling fluid may have light refractive properties, and the path of flow of the cooling fluid may be designed to direct radiant heat or light emitted from the lamp bulbs 70 , 72 toward the semiconductor wafer 64 .
As shown in FIGS. 2 and 2A, the chamber 62 has first and second arrays of quartz enclosures 74 , 76 , with each quartz enclosure containing a respective lamp 70 , 72 . The quartz enclosures 74 , 76 , and liners 66 , 68 , help to isolate the lamp bulbs from the chamber 62 so as to maintain the inner portion of the chamber 62 that houses the wafer during RTP processing free from contaminants without introducing large thermal masses between the light source(s) and the wafer.
Optional vacuum lines 101 may be used to evacuate gases from the chamber 62 to draw a vacuum within the chamber. The vacuum lines are shown in phantom outline in FIG. 2 A.
Although not shown in FIG. 2, it is of course possible to use liners with different thicknesses to isolate the first and second lamp arrays from the chamber 62 . For example, a thinner liner with a nominal thickness of 0.25 mm may be suitable to isolate the first lamp array, and may have the advantage of permitting a faster temperature response and higher temperature ramp up.
FIG. 3 is a section view of an alternate embodiment 90 of the invention which provides for additional contamination protection for a wafer 64 supported on the wafer supports 65 . In the embodiment of FIG. 3, windows 86 and 88 fully extend to the sides of the housing defining the chambers 62 , 95 to form a sealed enclosure for the wafer supports 65 to better isolate the wafer 64 and wafer supports 65 from contaminants that might be emitted by the lamps 70 , 72 or enclosures 74 , 76 surrounding the lamps. To maintain pressure equilibrium on each side of the windows 86 and 88 , thereby avoiding the need for thick and thermally massive quartz windows as were used in prior art RTP apparatus, the pressures on both sides of quartz windows 86 and 88 are controlled. In the embodiment shown in FIG. 3, a vacuum is drawn through pressure pump 92 , and regulators 94 and 96 equalize the pressure on each side of the window plates 86 and 88 through conducting lines 98 , 100 and 102 . Appropriate seals 104 between the sidewalls of the chambers 62 and 95 and the windows 86 , 88 maintain a substantially contaminant free environment under vacuum within the chambers 62 and 95 .
As a further enhancement to the apparatus for rapid thermal processing, the amount of radiant energy delivered from the lamps 70 , 72 to the chamber 62 containing the wafer 64 may be optimized by varying the characteristics of the envelope encompassing the lamp bulbs. FIG. 4 represents a section view of one of the transparent enclosures 74 from one of the lamp arrays 70 . In this embodiment, the transparent enclosure is a quartz tube 74 a that has been coated on an inner surface with a reflective coating 106 that helps to direct radiant energy from the bulb 70 to the wafer 64 on the wafer supports 65 . Preferred reflective coating materials are gold, or other infrared reflective coatings, such as TiO 2 and Al 2 O 3 . The inner reflective coating 106 is shown covering less than 180° of the quartz tube 74 a as defined by angle A in FIG. 4 . Preferably, angle A is within the range of about 160 to 180°. By controlling the radiant energy intensity within the area in which the wafer is processed, improved temperature stability may be realized, resulting in better process repeatability.
FIG. 5 is a section view of an alternative arrangement in which a reflective coating 108 is applied to the outside surface of a lamp bulb 70 a to direct radiant energy towards the wafer held within the chamber 62 .
FIG. 6 shows in section view another embodiment in which a reflective coating 110 is applied to coat the outside surface of the transparent enclosure 74 b surrounding the lamp bulb 70 . Coating the outside surface directs radiant energy toward the wafer in the chamber 62 , but with a different pattern than that produced when a coating 106 is applied to the inner surface of the transparent enclosure 74 a (shown in FIG. 4 ).
A parabolic reflector 112 may be provided adjacent to the transparent enclosure 74 surrounding the bulb 70 . As shown in FIG. 7, the parabolic reflector 112 serves to direct emitted radiation toward the wafer in straighter, more parallel paths, as compared to the reflective coating 110 applied to the outside surface of the transparent enclosure in FIG. 6, which reflects radiation in more divergent paths. Parabolic reflectors that direct emitted radiation toward the wafer in straighter, more parallel paths are preferred.
The benefits of straighter, more parallel paths for radiation may be obtained even when the reflective coating 110 is applied to the outer surface of the transparent enclosure 74 b by introducing straight reflectors 114 adjacent to the transparent enclosure 74 b as shown in FIG. 8 . The straight reflectors 114 in combination with the reflective coating serve to direct the emitted radiation toward the semiconductor wafer. When the reflectors 114 are disposed between adjacent transparent enclosures in an array of enclosed lamps, the reflective surfaces of the reflectors 114 redirect some divergent radiation rays toward the wafer 64 in the chamber 62 .
The top and bottom walls of the apparatus 60 or 90 alternatively may be formed as one or a series of channel-like cavities of parabolic reflective shapes 116 , as shown best in FIG. 9 . FIG. 9 is a cross section of taken from an end elevation of the upper portion of a chamber. In such an embodiment, each lamp 70 enclosed within a transparent enclosure 74 is held within a parabolic channel 116 formed within the chamber wall 93 . With fewer separate parts for assembly, this embodiment may produce fewer contaminants than when the reflective structure is formed from separate parts or separate coatings associated with the transparent enclosures around the lamps. In addition, the openings of the parabolic channels 116 may also be covered with an optically transparent window (not shown in FIG. 9 ).
The foregoing embodiments, which provide for individual sealing of linear lamps with optically transparent enclosures, such as quartz tubes, eliminate the thicker and expensive quartz plates or windows used in conventional systems. Moreover, the optically transparent enclosures around the lamps can have cross-sectional shapes that improve the ability of the enclosures to withstand higher atmospheric pressures. For example, circular or parabolic cross-sectional shapes can withstand greater pressures than other cross sectional shapes with flatter surfaces. Nevertheless, other cross sectional shapes may also be used depending on the extent of the vacuum drawn or pressure differential between the chamber interior and exterior.
FIGS. 10A-10F illustrate various embodiments for supporting a linear lamp 70 on or within the wall 93 of the chamber 62 . FIG. 10A shows a bulb 70 surrounded by a quartz tube 74 and positioned closely adjacent to the side wall 93 of the chamber. Alternatively, FIG. 10B shows a bulb 70 surrounded by a quartz tube 74 , wherein the tube is embedded partially within a cavity formed within the sidewall 93 of the chamber. As yet another alternative, FIG. 10C shows a bulb 70 surrounded by a quartz tube 74 , wherein the tube is completely embedded within an arcuate cavity 118 formed within the sidewall 93 of the chamber. The arcuate cavity 118 has a depth sufficient to hold the entire tube 74 .
In FIG. 10D the bulb 70 is held within a cavity 118 with an arcuate base. The opening of the cavity 118 is sealed with a flat cover 120 formed of optically transparent material, such as quartz. In such embodiment, there is no tube enclosing the bulb, but the bulb is isolated from the interior of the chamber by the cover 120 . As an alternate to this approach, in FIG. 10E, the bulb 70 is held within a cavity 118 with an arcuate base formed within the wall 93 of the chamber, and a curved cover 122 of transparent material, such as quartz, seals the cavity opening. The curved cover 122 is preferably shaped as a convexly curved lens, to help focus and direct radiant energy from the lamp bulb 70 to the wafer held within the chamber.
Further efficiencies may result by enclosing multiple lamp bulbs within a single transparent enclosure. FIG. 10F shows bulbs 70 c and 70 d enclosed within quartz tube 74 . The tube 74 is positioned closely adjacent the wall 93 of the chamber. Multiple lamps in a lamp array may be used as a heating source in the RTP system, but the benefits of the invention do not require a one to one relationship between the transparent enclosure and the bulb surrounded by such enclosure.
Rather than a tube-like structure, the optically transparent enclosure may be formed in other geometric shapes with varying cross-sections. For example, in FIG. 12, the bulb 70 may be held within a cavity formed within a solid piece 124 of an optically transparent material. The solid piece is attached to the wall 93 of the chamber, and has been shaped on one side to form a concavely curved lens to help direct and focus radiant energy emitted by the bulb 70 .
In yet another embodiment shown in FIG. 13, a solid block 126 of optically transparent material is held within a cavity 130 formed within the wall 93 of the chamber. A bulb 70 is held within a hollow portion of the solid block. The cooling channels 128 are provided within the cavity 130 and around the solid block 126 to permit flow of a cooling fluid, such as liquid or gas, to help to cool the block 126 and the lamp bulb 70 . Preferably, the cooling channels 128 are held within a potting or sealing material 129 that seals the block 126 within the cavity 130 .
The principle of the invention can be equally applied to point lamps, rather than the linear lamps shown in the embodiments of FIGS. 2 and 3. The top wall 144 of an RTP system 140 that uses point lamps 142 as the heating source is shown in FIG. 14 . In such an embodiment, the bulbs 142 are held within sockets so that the bulb portion extends perpendicularly to the semiconductor substrate, such as a semiconductor wafer, held within a chamber for processing. As shown in FIG. 14, the bulbs are aligned in rows and held within troughs. As one embodiment of the invention using an RTP system 140 with point lamps 142 , strips of transparent optical enclosure material (not shown) cover the troughs holding the bulbs to isolate the bulbs from the chamber holding the wafer to be processed.
Alternatively, as shown in FIG. 11A, each individual lamp bulb 142 held within a socket (not shown) in the wall 144 can be enclosed within an optically transparent enclosure 146 to isolate the lamp 142 from the interior of the chamber. To help direct radiant energy emitted from the lamp bulb 142 toward the wafer to be processed, the bulb 142 may be held within a light pipe 148 , and the bulb and light pipe together enclosed within an optically transparent enclosure as shown in FIG. 11 B. In FIGS. 11A and 11B, the optically transparent enclosure 146 has a curved or parabolic shape to better withstand pressures and forces thereupon when the pressure is changed within the chamber.
FIG. 11C shows the arrangement where an individual point lamp 142 is enclosed within a light pipe 148 , wherein the proximal end of the light pipe 148 is attached to the wall 144 of the chamber. The distal end of the light pipe 148 is then enclosed with a curved or parabolic-shaped optically transparent enclosure 150 to seal the cavity formed by the light pipe and the enclosure and isolate bulb 142 from the wafer to prevent contamination from the bulb from reaching the wafer. In FIG. 11D, the point lamp 142 is held within a cavity or recess 152 within the wall 144 of the chamber. A smaller amount of quartz or other optically transparent material may be used in the curved or parabolic-shaped cover 146 to cover the cavity opening and isolate the bulb from the wafer to be processed.
While each of the foregoing embodiments of FIGS. 11A-D is shown with a curved quartz enclosure around the point lights 142 or point lights 142 in combination with a light pipe 148 , it is of course possible to locate each of the bulbs within a recess or cavity in the chamber wall 144 , and provide a single flat covering of quartz to seal each of the lamps against the pressure differential within enclosure.
The foregoing examples for controlling the dispersion of radiant heat energy from the lamps 70 , 72 , 142 are exemplary only. It is clear that a judicious selection of the lamps, reflective coatings, and lens surfaces will provide an even higher degree of control over radiant light into the processing chamber. The foregoing illustrations and descriptions of the preferred embodiments have shown these relationships as fixed. Nevertheless, they may be augmented by positioning devices which move the radiant lamps with respect to reflective surfaces and lenses. While the positions of these elements for controlling light/energy dispersion from the lamps has been described in the context of uniform light distribution over the interior surface of a wafer held within the chamber, such as chamber 62 or chamber 91 , it is clear that the lamps and lamp arrays may be positioned to control the temperature profile within the enclosure.
Another alternate embodiment of the invention is shown in FIG. 15 . In this embodiment, throughput is increased by placing two semiconductor wafers 64 onto wafer holders 65 within the chamber for simultaneous processing. Optically transparent liners 66 and 68 , which may be quartz, do not form a pressure sealing surface with the chamber 62 ′, but are supported within the chamber 62 ′ so that the pressure is equalized on each side of the liners 66 and 68 . First and second arrays of light sources, such as tungsten halogen heating lamps or Xenon arc lamps, are provided along the top and bottom of the chamber 62 ′, i.e., above and below the wafer supports 65 . The arrays of light sources along the top and bottom of the chamber 62 ′ supply direct radiant heat to the wafers 64 as the wafers are held on the wafer supports 65 . Each light source includes a linear lamp 70 , 72 within an optically transparent enclosure (such as a quartz tube) 74 , 76 on the top and bottom of chamber 62 ′. The quartz tubes 74 , 76 individually surround each lamp 70 , 72 , and are sealed to the sidewalls of chamber 62 ′ with seals 78 , 80 , thus maintaining both the area surrounding the quartz tubes 74 , 76 and the remaining portion of the chamber 62 at the same pressure, preferably under vacuum. The lamps 70 in the upper array are arranged in a direction perpendicular to the lamps 72 in the lower array.
Individual cooling channels having an inlet 82 and an outlet 84 circulate cooling fluid, such as a liquid like water or a cooling oil, or a gas with suitable thermal conductivity like air, or a mixture of air and helium or hydrogen, through each quartz tube 74 , 76 to cool the lamps 70 , 72 . The cooling fluid may have light refractive properties, and the path of flow of the cooling fluid may be designed to direct radiant heat or light emitted from the lamp bulbs 70 , 72 toward the semiconductor wafer 64 .
The top and bottom walls 91 , 93 of the chamber 62 may be coated with a reflective coating 69 , such as metallic gold or other infrared reflective coatings, such as TiO 2 and Al 2 O 3 .
As shown in FIG. 15, the chamber 62 ′ has first and second arrays of quartz enclosures 74 , 76 , with each quartz enclosure containing a respective lamp 70 , 72 . The quartz enclosures 74 , 76 , and liners 66 , 68 , help to isolate the lamp bulbs from the chamber 62 so as to maintain the inner portion of the chamber 62 that houses the wafers during RTP processing free from contaminants without introducing large thermal masses between the light source(s) and the wafers.
FIG. 16 shows yet another alternate embodiment of the apparatus, in which a plurality of point lamps 142 held within sockets 160 mounted in the outer walls 162 of the chamber 62 ″ are positioned to direct radiant energy toward a wafer 64 held on wafer supports 65 within the chamber 62 ″. The point lamps 142 preferably are surrounded by quartz envelopes 164 to minimize emission of contaminates. In addition, a series of optically transparent liners 166 , preferably of quartz, are placed over openings in the inner wall 168 of the chamber 62 ″ to further shield the point lamps 142 from the wafer 64 held within the chamber 62 ″. The liners 166 are sealed to the inner wall 168 with seals 169 . Preferably, channels 170 , 172 formed in the chamber walls permit cooling fluid, such as a gas, to be circulated past the point lamps 142 to cool the lamps 142 . These channels 170 , 172 also permit gases to be introduced into and removed from the chamber 62 ″ to help stabilize or equalize the pressure in the portions 174 of the chamber 62 ″ enclosing the point lamps 142 and the portion of the chamber 62 ″ enclosing the wafer 64 for processing.
The invention also comprises such embodiments in which features of the above mentioned embodiments are exchanged and/or combined in whole or in part.
The foregoing description of the invention illustrates and describes the preferred embodiments of the invention. Nevertheless, it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings and/or the skill or knowledge of the relevant art. The description is not intended to limit the invention to the form disclosed herein. Alternate embodiments apparent to those of skilled in the art are to be included within the scope of the appended claims.
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In a rapid thermal processing system an array of heat lamps generate radiant heat for heating the surfaces of a semiconductor substrate, such as a semiconductor wafer, to a selected temperature or set of temperatures while held within an enclosed chamber. The heat lamps are surrounded individually or in groups by one or more optically transparent enclosures that isolate the heat lamps from the chamber environment and the wafer or wafers therein. The optically transparent enclosures may include associated reflectors and/or lenses to direct a higher proportion of emitted radiant heat energy from the lamps toward the semiconductor wafer(s). Thin planar quartz liners may also be interposed between the lamps and the substrate. By controlling radiant energy distribution within the chamber, and eliminating thick planar quartz windows commonly used to isolate the lamps in prior art RTP systems, higher processing rates and improved reliability are obtained.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to International Application No. PCT/EP2012/001432 filed on Mar. 31, 2012 and German Application No. 10 2011 018 749.9 filed on Apr. 27, 2011, the contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to a method for activating a function of a vehicle, which is associated with a key which wirelessly interchanges data with the vehicle.
[0003] The function is intended to be able to be activated with the method, in particular from a distance which is too large for interchanging data with the key. It is appropriate here to use a (particularly portable) telecommunications device, for example a mobile radio telephone, which is different from the key in order to pass a command for activating the function to the vehicle via a telecommunications link (via mobile radio).
[0004] For example, it is conceivable for the function to be activated to concern the auxiliary heating of the vehicle. The user of the vehicle has parked the latter at an airport, has flown to a different location and is just about to board the aircraft back to the vehicle. The user wants the vehicle to be preheated when he arrives there again. However, in order to operate the auxiliary heating, it must be ensured that the vehicle is on particular terrain where there is no danger of fire. The situation in which another user, for example the user's wife, has moved the vehicle away and the vehicle is then on different terrain than the user thinks should be avoided.
[0005] If the desire is therefore to activate a function of a vehicle with the aid of a telecommunications device, rather than with the vehicle key, a sufficient level of safety must be ensured.
[0006] DE 10 2009 035 654 A1 discloses the practice of mechanically coupling a vehicle key to a radio module. In this case, provision may also be made for there to be a communication link between the vehicle key and the radio module. However, in DE 10 2009 035 654 A1, all commands are passed to the vehicle solely by the vehicle key. Therefore, it is not possible to activate functions of a vehicle from a distance which is too large for interchanging data with the key.
[0007] EP 1 216 900 A1 describes a remote communication system for a motor vehicle, a first communication unit being arranged in the vehicle and a portable second communication unit, for example a key, being wirelessly and communicatively connected to a telecommunications unit, for example a mobile telephone, which can be used to transmit data in a bidirectional manner between the portable communication unit and the first communication unit in the vehicle over long distances, in particular for the purpose of activating a function of the vehicle. In addition, the second communication unit may comprise a biometric sensor in order to identify a user and to prevent unauthorized remote operation of the motor vehicle. Furthermore, the two communication units may comprise an identification unit. In this case, an identification code may be transmitted, for example, from the second communication unit to the first communication unit. If the identification code is accepted by the first communication unit, a communicative link may be established. If a plurality of portable second communication units are associated with the vehicle, each portable communication unit is assigned a rank, with the result that, in the event of contradictory commands from two or more portable communication units, priority is given to that command from the portable communication unit with the higher rank.
[0008] US 2006/294429 A1 describes a method for deleting a local operation which was previously carried out, in particular activation of a function of a vehicle. In this case, when a function of a vehicle is activated by a key, data relating to this function, the key ID and the activation time and date are first of all stored in a memory element connected to the key and in a further memory element in the vehicle. If the activated function is intended to be deactivated by a key from a great distance, the information stored in the key is compared with the information stored in the vehicle and the activated function is deactivated only if the items of information correspond. In this case, an item of comparative information is not obtained for the purpose of activating a function.
[0009] EP 2 264 980 A1 describes a communication system having a telematic unit fixed to the vehicle and a communication device which is communicatively connected to the telematic unit. In this case, a plurality of communication paths are available, by which the communication device can communicate with the telematic unit and which have a different range. In this case, a suitable communication path can be selected on the basis of the distance between the communication device and the telematic unit. Furthermore, the communication device may also comprise security data for authorizing communication between the communication device and the telematic unit.
SUMMARY
[0010] One possible object is to enable remote activation of a function of a vehicle which is sufficiently safe.
[0011] According to the inventors' proposals, a function of a vehicle, which is associated with a key which wirelessly interchanges data with the vehicle, is activated with the aid of a telecommunications device which is different from the key. The telecommunications device is connected to the key in order to establish communication and receives an item of information from the key. The information is compared with an item of comparative information and a function of the vehicle is activated if the information corresponds to the comparative information (according to a predetermined criterion), the comparative information representing an item of information relating to the key used last to activate a function on the vehicle.
[0012] The proposals thus involve the telecommunications device searching for the key, in particular in its environment, and the key is included in the method sequence in this manner. Everything which can be implemented by the key with respect to safety can therefore now also be implemented by the telecommunications device.
[0013] One particularly preferred embodiment involves the telecommunications device first of all obtaining the comparative information from the vehicle (for example, a mobile radio telephone thus calls the vehicle and receives the comparative information in response). After receiving the information during or as a result of communication with the key, the telecommunications device then transmits an activation signal to the vehicle if the information received corresponds to the comparative information.
[0014] In this manner, the software implemented on the telecommunications device ensures a sufficient level of safety, with the result that there is no need to install software matching the software of the telecommunications device on the vehicle and/or the key if the basic functionality of interchanging data is provided. The responsibility for the method therefore lies with the telecommunications device, which can be conveniently equipped with corresponding software (“applet”).
[0015] As an alternative to this embodiment, it is naturally also possible, in principle, for the telecommunications device to first of all receive an item of information as a result of communication with the key and to forward this information, together with an activation signal, to the vehicle. However, unlike in the embodiment described above, this activation signal does not immediately activate a function, but rather the vehicle compares the forwarded information with an item of comparative information stored in a memory of the vehicle. The vehicle then automatically activates the function if the items of information correspond to one another. In this case, it is necessary for the vehicle itself to be equipped with a functionality comprising the reception of information, the comparison with comparative information and the automatic activation of a further functionality. However, this embodiment is advantageous if an automobile manufacturer would already like to provide particular functionalities in a visible manner.
[0016] In one embodiment, the information obtained identifies the key as one of a plurality of vehicle keys. In this case, if the telecommunications device attempts to set up a communication link to the key, the key only needs to emit a conventional response signal which identifies it. There is no need to transmit separate information. This embodiment is impressive as a result of its simplicity.
[0017] On the other hand, it is possible for the information received to be an item of information which is transmitted by the key and was stored on the latter after the key last interchanged data with the vehicle. For example, the transmitted information may comprise the time of the last ignition change, that is to say when the vehicle was last switched on or off. If the time of the ignition change stored on the key is compared with the time of the last ignition change stored in the motor vehicle, it is possible to avoid the situation in which the vehicle has been moved away with the aid of a key other than the key carried together with the telecommunications device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0019] FIG. 1 is a diagram for explaining the sequence of steps in a first embodiment of the proposed method, and
[0020] FIG. 2 is a corresponding diagram for explaining a sequence of steps in a second embodiment of the proposed method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0022] The present case starts from the basic situation in which a vehicle has been moved with the aid of a particular key and has then been parked. The vehicle driver takes the key with him and simultaneously carries a mobile device (mobile radio telephone). He proceeds to a location which is so far away from the vehicle that it is not possible to establish a wireless link between the key and the vehicle.
[0023] However, the present case assumes that the mobile device can communicate with the vehicle, in particular via a mobile radio network, and that the mobile device can simultaneously communicate with the key, in particular via a Bluetooth interface or another wireless interface.
[0024] The first embodiment of the proposed method begins with an input in step S 10 , by which the user attempts to activate the auxiliary heating of the vehicle. The user knows that he has parked the vehicle on terrain on which the auxiliary heating can be safely operated.
[0025] After the input in step S 10 , the mobile device automatically transmits a query to the vehicle in step S 12 in order to find out from the vehicle what key was used last to activate a function on the vehicle. The vehicle receives this query and automatically transmits the information regarding the key used last to the mobile device in step S 14 . The information is represented, for example, in the form of a key code which can also be used for the communication interface between the mobile device and the key. The mobile device then searches for the key used last in step S 16 . It is sufficient for the key to provide feedback in step S 18 so that it is clear that exactly the key which was used last to move the vehicle is located in the region of the mobile device. It is thus clear that the vehicle has not been moved away from the terrain on which the user parked it. Therefore, the mobile network automatically activates the auxiliary heating of the vehicle in step S 20 . No further check of the activation signal takes place in the vehicle.
[0026] In a second embodiment of the proposed method, an input, according to which the auxiliary heating should be activated, is made by the user in step S 110 . In a query in step S 112 , the mobile device now queries with the vehicle when the time of the last ignition change was. As long as the vehicle has not been moved by anyone else, this is the time at which the ignition of the vehicle was switched off by the present user.
[0027] In step S 114 , the vehicle automatically transmits the information relating to the last ignition change.
[0028] The mobile device now generally searches for (vehicle) keys or specifically for a particular key whose code is stored in it, see step S 116 . The device then receives feedback from the key in step S 118 , with the result that a communication link has been established between the key and the mobile device. In step S 120 , the mobile device then automatically transmits a request for the ignition change stored in the key. It is assumed here that, for each ignition change, the corresponding time is stored in the key. The information relating to the ignition change stored last is then transmitted from the key to the mobile device in step S 122 . The device can now compare the two items of information received from the vehicle, on the one hand, and from the key, on the other hand, with one another in step S 124 . If said ignition changes correspond to one another, this means that the vehicle has not been moved with the aid of another key, that is to say that no further ignition change took place. It is therefore ensured that the vehicle is on exactly the terrain on which its user parked it. In step S 126 , the auxiliary heating can therefore be activated, to be precise automatically by the mobile device, and the vehicle only reacts thereto.
[0029] The method in the embodiments described is initiated and carried out by the mobile device. This has the advantage that it is possible to carry out the method by implementing suitable software on the mobile device (“applet”). As an alternative, it is possible to allow some portions of the method to be carried out by the vehicle. Although an input would then have to be made on the mobile device and communication with the key would also be effected by the mobile device, other steps, for instance the comparison of obtained information, could then be carried out in the vehicle itself.
[0030] The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide V. DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004).
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A method for activating a function of a vehicle, which is associated with a key which wirelessly interchanges data with the vehicle, is carried out with the aid of a telecommunications device which is different from the key. However, the telecommunications device attempts to communicate with the key in order to make the method safe. During communication with the key, an item of information is obtained and is compared with an item of comparative information.
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The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/000,694, entitled NUTT SO RUFF SCRUB BAR and filed on Oct. 29, 2007. The disclosure of that application is hereby fully incorporated by reference herein.
BACKGROUND
The present disclosure relates to exfoliating products that are used to exfoliate various parts of the body.
Exfoliation is a process in which the surface layer of dead skin cells is removed. While the skin will exfoliate on its own, manual exfoliation removes dead skin cells and increases circulation. The result is softer, smoother, healthier glowing skin. Exfoliation is especially helpful for oily skin because oil clogs skin pores, which could cause unsightly acne blackheads. Exfoliation also helps dry skin, which otherwise tends to look dull. Because dead skin cells generally accumulate faster than natural exfoliation, the skin's natural exfoliating ability and moisture absorption ability are inhibited. Regular exfoliation thus allows the skin to absorb more moisture, reduce fine lines from wrinkles, and decrease acne.
Traditional means of exfoliation include using pumice stones, corn/callus removers, chemical peels, and facials. Pumice stones operate as an abrasive, and therefore do not provide gentle skin exfoliation. Corn/callus removers typically include a sharp blade, which can be dangerous if improperly used. Such situations are common because corn/callus removers are typically used with running water, such as in a sink or during a shower. Wet hands increase the chance that the remover will slip from the hand and cause cuts. Chemical peels and facials can be expensive. Patients can also have severe skin reactions, such as breakouts and skin redness.
There are some over-the-counter products that attempt to aid exfoliation as well. Many of these products come in the form of gels or pastes. As a result they can be messy to use. Some of these over-the-counter products can also be harsh to sensitive skin. In addition, gels and pastes are hard to use without making a mess, and are especially difficult to use in the shower.
It would be desirable to provide an exfoliation product that can be used on various parts of the body, depending on skin sensitivity, and can be used on a daily basis if desired. Such a product should also be effective at removing dead skin, but gentle on the skin.
BRIEF DESCRIPTION
Disclosed in various embodiments is a scrub bar that uses natural ingredients to exfoliate the skin gently and effectively. The bar form allows a person to use the scrub bar in the shower and easily cleanse themselves.
Disclosed in embodiments is a scrub bar comprising three ingredients: powdered or crushed nuts; powdered or crushed oats; and glycerin. In some embodiments, the scrub bar consists of the nuts, oats, and glycerin.
In particular embodiments, the nuts comprise from about 6 to about 12.5 weight percent of the scrub bar. The oats may also comprise from about 6 to about 12.5 weight percent of such embodiments.
In other embodiments, the oats comprise from about 6 to about 12.5 weight percent of the scrub bar.
In some embodiments, the nuts comprise about 6.25 weight percent of the scrub bar and the oats comprise about 6.25 weight percent of the scrub bar. In additional embodiments, the nuts comprise about 9.375 weight percent of the scrub bar and the oats comprise about 9.375 weight percent of the scrub bar. In yet other embodiments, the nuts comprise about 10 weight percent of the scrub bar and the oats comprise about 10 weight percent of the scrub bar.
The glycerin may comprise from about 75 to about 88 weight percent of the scrub bar.
Desirably, the nuts and oats have a particle size of 1 mm or less. Preferably, the nuts used in the scrub bar are almonds.
The scrub bar may not contain animal fats or oils, methyl alcohol or ethyl alcohol, a colorant, or an odorant.
Sometimes, the oats and nuts are evenly dispersed throughout the glycerin. However, the oats and nuts may also be preferentially located near a surface of the scrub bar.
Disclosed in other embodiments is a scrub bar comprising: from about 6 to about 12.5 weight percent of powdered or crushed nuts; from about 6 to about 12.5 weight percent of powdered or crushed oats; and from about 75 to about 88 weight percent of glycerin; wherein the weight ratio of nuts to oats is about 1:1.
Also disclosed is a method for producing a scrub bar. Liquid glycerin is provided in a container. The powdered or crushed nuts and oats are added to the liquid glycerin. The liquid glycerin is mixed to disperse the nuts and oats, thereby forming a mixture. The mixture is poured into a mold and cooled to form the scrub bar.
These and other non-limiting characteristics of the present disclosure are more particularly described below.
DETAILED DESCRIPTION
The scrub bar of the present disclosure comprises (a) powdered or crushed nuts; (b) powdered or crushed oats; and (c) glycerin. In some embodiments, the scrub bar consists of the nuts, oats, and glycerin only.
In embodiments, the powdered or crushed nuts are each present in the amount of from about 6 to about 12.5 weight percent of the scrub bar. The term “nut” refers generally to a kernel found within a shell or husk. Although any nut can be used, generally peanuts are avoided due to peanut allergies amongst the general population. Desirably, crushed or powdered almonds are used. Other nuts which may be useful in the scrub bar of the present disclosure include almonds, walnuts, chestnuts, pecans, cashews, macadamia nuts, and pistachios.
In embodiments, the powdered or crushed oats are each present in the amount of from about 6 to about 12.5 weight percent of the scrub bar.
The nuts and oats are powdered or crushed. In other words, they are processed from their original intact state into a less than intact state where they have particle sizes of from 0.1 mm to 3 mm. Desirably, the nuts and oats, once powdered or crushed, can pass through a sieve having a sieve size of 1 mm, i.e. so that the particle size is 1 mm or less. For example, the powdered or crushed nuts/oats can be generally obtained by passing intact nuts/oats through a food processor, running through a sieve, and returning the un-passed material through the food processor again. The powdered or crushed nuts/oats generally have a consistency similar to that of a powder or soft sand.
Depending on the degree of abrasiveness desired in the scrub bar, the amount of nuts and oats will vary. Generally, the nuts and oats are present in a weight ratio of about 1:1 nuts:oats. Generally, the greater the amount of nuts and oats, the more abrasive the scrub bar will be. In specific embodiments, the nuts comprise about 6.25 weight percent of the scrub bar and the oats comprise about 6.25 weight percent of the scrub bar. In other embodiments, the nuts comprise about 9.375 weight percent of the scrub bar and the oats comprise about 9.375 weight percent of the scrub bar. In still other embodiments, the nuts comprise about 10 weight percent of the scrub bar and the oats comprise about 10 weight percent of the scrub bar. The nuts and oats provide an abrasive surface for effective exfoliation, but are gentle to the skin, unlike harsh pumice.
The glycerin serves as a base in which the nuts and oats are dispersed. The glycerin may comprise from about 75 to about 88 weight percent of the scrub bar. As used here, the term “glycerin” does not refer to the specific chemical compound also known as glycerol(1,2,3-propanetriol). Instead, the term “glycerin” refers to the common soap base generally formed from the reaction of a fat and lye, which can contain ˜7-20% pure glycerol.
Desirably, the scrub bar contains natural ingredients. In particular, the scrub bar does not contain animal fats or oils, methyl alcohol or ethyl alcohol, colorants, or odorants in specific embodiments.
The oats and nuts may be evenly dispersed throughout the glycerin. In some embodiments, the oats and nuts are preferentially located near a surface of the scrub bar. Put another way, a majority (by weight) of the oats and nuts in the scrub bar are dispersed close to a surface of the scrub bar (rather than within the internal volume of the bar). The dispersion of the oats and nuts within the glycerin can be controlled by methods known in the art.
The scrub bar of the present disclosure can be made using methods known in the art. For example, the nuts and oats may be pulverized or powdered using devices such as a food processor. The degree of powdering can be controlled, for example, by using a sieve to obtain the desired powder size. Next the glycerin is provided in a liquid form, for example, by melting a solid glycerin base. The powdered or crushed nuts/oats are then added to the liquid glycerin. The liquid glycerin can be mixed, for example, by stirring, to disperse the nuts and oats within the glycerin. The degree of dispersion can be controlled by the amount of stirring. The mixture of glycerin, nuts, and oats can then be poured into a mold. The mold is then cooled to harden the scrub bar. Cooling is generally passive, in other words, the mold is simply left at room temperature until the liquid mixture has been cooled and hardens. If desired, active cooling, such as with water or air, may be used as well. The scrub bar is then removed from the mold by turning the mold upside down.
Exemplary embodiments include a soap bar containing 0.5 ounces of a nut/oat mixture with 3.5 ounces of glycerin; a soap bar containing 0.75 ounces of a nut/oat mixture with 3.25 ounces of glycerin; and a soap bar containing 0.75 ounces of a nut/oat mixture with 3 ounces of glycerin.
Although particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the claims as filed or as they may be amended are intended to embrace all such alternatives, modifications, variations, improvements, and substantial equivalents.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a tilted side view that shows the top and bottom of the exfoliating scrub bar of the present invention.
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An exfoliating scrub bar for various parts of the body is made from natural ingredients that exfoliate the skin gently and effectively. The scrub bar comprises powdered or crushed nuts; powdered or crushed oats; and glycerin. The combination of ingredients allows a person to gently exfoliate different parts of the body depending on the location and/or skin sensitivity. The scrub bar provides the user with an effective tool for exfoliation that allows for the removal of dead skin cells.
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BACKGROUND
[0001] The term “timber” by itself as used herein typically refers to a wood member suitable for use in the construction of a building or the like. Several main types of wood construction are generally known. These construction types use forms of timber available from logs to sawn/shaped timbers to branches and even leaves. These construction types also utilize various wall coverings from plant-based coverings to timber materials to earthen materials, such as mud or stone. One type of wood construction is thatch construction, which is generally a traditional construction type. Other types include post-and-beam frame construction, walls with bamboo/reed mesh and post (waffle and daub), wooden frames with or without infill, and stud-wall frames with plywood/gypsum board sheathing. Two other types are wood panel construction and log construction.
[0002] The origin of log building construction is uncertain. The first log structures are thought to have been built in Northern Europe about 3500 BC. Early techniques involved stacking tree trunks on top of each other and overlapping the corners resulting in some of the first log cabins. The strength of log structures was improved with interlocking corners made by notching the logs near the ends and overlapping the log in the notches. Such interlocking corners brought the logs closer together making it easier to seal the structure against the weather by stuffing the spaces between logs with moss or other materials.
[0003] Logs used in construction are often peeled of their bark. When using younger logs with a significant taper over length, such logs may be hewn to reduce the taper. Logs may also be hewn or otherwise cut to make them square or rectangular instead of round. Traditionally, round log building were often considered temporary until a more permanent structure could be built. But square log craftsmanship is considered the original permanent home design. Some advantages of square log over round include:
[0004] Square logs are typically made from the heart of a tree where shrinkage is minimal (typically less than 1 inch) as opposed to round logs with shrinkage of up to 5 inches. Thus, dealing with log shrinkage is much easier when using square logs.
[0005] Square logs can be fitted to better avoid water problems and associated rot than round logs. This results in longer building life. For example, square log homes over 500 years old are said to be common in Europe.
[0006] Square logs can be drilled for wiring and plumbing runs between courses while round logs, due to their shape, require chases or other methods of hiding wires and plumbing.
[0007] Unlike square logs, round logs tend to catch dust due to their shape. Round logs also make interior decorating more difficult due to their shape. Square logs, on the other hand, tend to be much easier for people to live with and keep clean. The term “square log” as used herein generally refers to a log or beam or timber or the like, composed of natural wood or any other material or combination of materials suitable for building construction, of some length, sections of which are substantially and consistently rectangular in shape, where one example of rectangular is square. Note that conventional square logs are made from natural wood and are typically fabricated as a single piece out of tree trunks.
[0008] For these advantages and more, modern log buildings built with square logs tend to enjoy a higher appraised value than round log buildings. In fact, the larger the square logs, the higher the value—and the cost. One reason for this is that square logs are generally cut from the heart of a tree and larger trees for making larger square logs tend to be scarce and expensive.
[0009] In recent times, log buildings have become increasingly popular for vacation cabins and even for homes. Various building techniques are combined to make such homes appealing and attractive. As a result, there is an increasing interest in and demand for log buildings and the timbers required to construct them. At the same time, the availability of old-growth timber suitable for producing larger logs is increasingly scarce and expensive.
SUMMARY
[0010] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the invention nor does it identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented below.
[0011] The detailed description discloses techniques for building construction using fabricated timbers. In one example, such timbers are fabricated using conventional 2× (two-by) lumber to produce a square log appearance. These fabricated timbers are then stacked to form outside and/or inside walls such as for a building. The fabricated timbers and walls are configured to sustain the vertical and lateral loads anticipated for a building such as a cabin, house, garage, barn, office building, or the like. A building constructed of such timbers appears to be built of square logs. Variations provide for chinking between courses of timbers, or for timbers stacked without chinking. The height of each log course can be as little as a few inches to well over a foot or more. With one variation, the height of a log course can appear to be several feet or more. The terms “stacked” and “stacked one atop another” and the like as used herein typically refer to multiple objects (e.g., fabricated timbers) where one such object is placed on the bottom, and another such object is placed on top of the bottom object, and so forth until a top object is placed on the top of the stack of objects, thus forming a vertical stack of the multiple objects.
[0012] The disclosed techniques can be used with any type of building foundation including crawl space, slab-on-grade, and full basement, and with any type of roof structure. Further, construction using pre-manufactured fabricated timbers requires far fewer steps over conventional log and stick frame structures, as illustrated in Table 1 below.
[0000]
TABLE 1
Fabricated
Conventional
Stick-Frame
Construction Steps
Timbers
Logs
& Stucco
Stack
A
B
Frame
X
Exterior sheathing
X
Fabricate utilities chases
C
Wire
X
X
X
Plumb
X
X
X
Insulate
X
Seal
X
Sheet rock
D
E
X
Tape
X
Mud
X
Sand
X
Texture
X
Interior molding
X
X
X
Interior prime
X
Interior paint
X
Vapor barrier
X
Chink
X
X
Windows
X
F
X
Doors
X
F
X
Exterior molding
X
X
X
Netting
X
Stucco
X
Stain/paint interior/exterior moldings
X
X
X
[0013] In Table 1, an ‘X’ indicates a required construction step. Table 1 indicates that construction based on fabricated timbers takes far fewer steps than conventional stick-frame construction (and is thus correspondingly less labor intensive), but is also simpler and less labor intensive that conventional log construction. The various letters other than ‘X’ indicate the following:
A: stacking can be performed by two or three people without the use of heavy equipment such as a crane. B: stacking requires the use of heavy equipment such as a crane. C: Fabrication of chases for wiring and plumbing and the like in conventional log construction is very labor intensive and costly. This expensive step is not required when using fabricated timbers. D: Due to very limited shrinkage of walls made of fabricated timbers (made from kiln dried lumber, typically less than 1″ for a 10′ wall), such walls can be wall-boarded if desired several months after construction. E: Due to significant shrinkage of conventional log walls (typically several inches for a 10′ wall), wall-boarding is generally not possible. F: Due to significant shrinkage of conventional log walls (typically several inches for a 10′ wall), installation of doors and windows requires extra-large cut-outs to accommodate shrinking over time, and may require adjusting moldings over time to account for shifting due to shrinkage.
[0020] Further, the R-value achievable by fabricated timbers typically ranges from 2.5 to 4 per inch of wall thickness, depending on the insulating material used inside and the height of the fabricated timber. For example, a fabricated timber using a 2×12 wood horizontal member typically provides an R-value of about R-40. In general, the taller each timber is in a wall, the greater the R-value provided by the wall. Further, taller and wider timbers tend to be more desirable because they can be made to have the appearance of tall and wide conventional logs which are very desirable due to the scarcity and high cost.
[0021] In addition, insulating materials that can be used in fabricated timbers may range from straw to conventional fiberglass wool, shredded paper (cellulose), or any other material that can provide a desired R-value, thus providing relatively low-cost, high-R-value walls. On the other hand, a conventional square logs typically provide an R-value of less than 2 per inch of log thickness. And a conventional 2×6 stick-frame wall typically provides approximately R-value of about 20. Thus, given fabricated timber construction, buildings that are far more heat-efficient can be easily and inexpensively constructed that also use far fewer materials and construction steps than conventional stick-frame construction, and at significantly lower cost and higher thermal efficiency than conventional log construction, yet with the high appraised values of high-quality conventional log construction. The term “R-value” as used herein is a conventional term that typically refers to the capacity of a material to resist heat flow.
[0022] Many of the attendant features will be more readily appreciated as the same become better understood by reference to the following detailed description considered in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0023] The present description will be better understood from the following detailed description considered in connection with the accompanying drawings, wherein:
[0024] FIG. 1 a is a diagram showing an end view 100 a of an example fabricated timber with a 3-dimensional view 100 b of the same example fabricated timber illustrated in FIG. 1 b.
[0025] FIG. 2 a is a diagram showing a top view of an example fabricated timber 100 .
[0026] FIG. 2 b is a diagram showing an end view of the example fabricated timber 100 .
[0027] FIG. 3 is a diagram showing an example wall 300 constructed from a plurality of example fabricated timbers.
[0028] FIG. 4 is a diagram showing an example method 400 for constructing a fabricated timber.
[0029] FIG. 5 is a diagram showing an example method 500 for constructing a wall from fabricated timbers.
[0030] FIG. 6 a is a diagram showing an end view 600 a of an example alternate fabricated timber with a 3-dimensional view 600 b of the same example alternate fabricated timber illustrated in FIG. 6 b.
[0031] FIG. 7 is a diagram showing an example wall 700 constructed from a plurality of example alternate fabricated timbers.
[0032] FIG. 8 illustrates an example of construction of a tall fabricated timber that has the appearance of an expensive solid tall wood timber.
[0033] FIG. 9 illustrates an example of construction of a single-reveal fabricated timber that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side.
[0034] FIG. 10 illustrates an example of construction of a single-reveal alternate fabricated timber that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side.
[0035] FIG. 11 illustrates front and side views of an example fabricated timber end cap.
[0036] Like reference numerals are typically used to designate like elements in the accompanying drawings.
DETAILED DESCRIPTION
[0037] The detailed description provided below in connection with the accompanying drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present examples may be constructed or utilized. The description sets forth at least some of the functions of the examples and/or the sequence of steps for constructing and operating the examples. However, the same or equivalent functions and sequences may be accomplished by different examples.
[0038] Although the present examples are described and illustrated herein as being implemented for building construction, the techniques described are provided as examples and not limitations. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of construction or the like.
[0039] FIG. 1 a is a diagram showing an end view 100 a of an example fabricated timber with a 3-dimensional view 100 b of the same example fabricated timber illustrated in FIG. 1 b . Such a timber according to this example is typically fabricated with two vertical members (e.g., members 110 and 120 ) of thickness t v and height h disposed on a horizontal member (e.g., member 130 ) of thickness t h and width w, each of the three members having substantially the same length l. In one example, the length l of the various members is from one to thirty feet, the height of the vertical members is from three to fifty inches, the width of the horizontal member is from three to thirty inches, and the thickness of the various members is from one to four inches. In other examples, the lengths l of the members may vary from one another, as may the thicknesses t v of 110 , t v of 120 , and t h of 130 . The surface measured by height h of the vertical members (e.g., 110 and 120 ) may represent a vertical plane of the members, and the surface measured by width w of the horizontal member (e.g., 130 ) may represent a horizontal plane of the member. The term “substantially” as used herein typically indicates “according to plan”, “nominally”, “conventionally”, and “customary” in relation to the arts of house-scale building construction as known to those of average skill in the art. The term “from n to m <units>” as used herein (e.g., from one to thirty feet) typically refers to a specific measurement based on a particular unit of measure (e.g., feet or inches or the like) that is ≧n and ≦m. For example, eight feet is a distance in feet that is from one to thirty feet. Thirty-nine feet, on the other hand, is not from one to thirty feet.
[0040] One vertical member 110 is typically disposed length-wise atop the left side L of horizontal member 130 , and the other vertical member 120 is typically disposed length-wise atop the right side R of horizontal member 130 , as illustrated in FIG. 1 b . Vertical members 110 and 120 typically have substantially the same height h. Each vertical member (e.g. 110 and 120 ) sits atop the horizontal member (e.g., 130 ) such that its height h is at an angle that is substantially perpendicular to or at a substantially 90 degree angle to the width w of the horizontal member (e.g., 130 ). The length l of supported vertical member 110 typically extends down the length l of horizontal member 130 , and the length l of supported vertical member 120 also typically extends down the length l of horizontal member 130 . Vertical members 110 and 120 are typically disposed length-wise atop horizontal member 130 so as to be substantially parallel with each other (e.g., 160 ), and to be substantially parallel with outer sides L and R of horizontal member 130 . In one example, the shape of each member may generally be described as cuboid comprising three opposing pairs of rectangular faces.
[0041] In some examples, vertical members 110 and 120 are fastened to horizontal member 130 using fasteners (e.g., 150 ) such as nails, screws, bolts, staples, pins, dowels, pegs, spikes, ties, strapping, adhesive, or the like. In one particular example, fastener 150 represents conventional 16d nails every n inches on center. The term “every n inches on center” as used herein refers to a fastener (e.g., a nail) installed so as to fasten the vertical member to the horizontal member as illustrated in FIG. 1 a , with such a fastener installed at least every n inches along the length l of the vertical and horizontal members, each such fastener approximately centered between the inner vertical face F i of the vertical member (e.g., 110 and 120 ) and the outer vertical face F o of the horizontal member (e.g., 130 ). One example of n may be 8. In other examples, other types or sizes of fasteners may be installed at other increments along the length l of the vertical and horizontal members. In further examples, a fabricated timber may be cast, extruded, molded, hewn, carved, cut, milled, or otherwise fabricated as a single piece rather than fabricated of separate members 110 , 120 , and 130 as shown in the examples of FIGS. 1 a and 1 b.
[0042] Note that the horizontal and vertical members of a fabricated timber form a channel 180 . This channel may be used for installing utilities such as electrical wires, gas and/or water lines, ducting, and the like. This channel may optionally be filled with insulation. Blocking may be added at the ends to keep insulation in, or ends may be covered with plastic, cardboard, or any other suitable material or the like to retail any insulation inside the fabricated timber. The term “blocking” as used herein typically refers to pieces of wood or other material (e.g., 224 ) disposed between members (e.g., 110 and 120 ) to provide support, attachment sites, or brace against lateral-torsion buckling, or the like.
[0043] The composition of fabricated timbers (e.g., 100 ) as described herein is not limited to wood, but may be plastic, fiber-cement, metal, laminated materials, composites, or the like, or any combination of such. In one example, conventional 2× lumber has been shown to be an inexpensive and readily available choice of materials that is simple to work with and that only requires commonly-available skills and tools. The term “2× lumber” or “two-by lumber” as used herein generally refers to softwood or conifer sized to nominal standardized dimensions as commonly used in construction of wood-buildings and the like, where the number ‘2’ in “2×” typically refers to the nominal pre-dried 2-inch thickness of the lumber which typically measures about 1.5 inches once dried. Such 2× lumber used in the construction of fabricated timbers and the like is typically kiln dried or the like. Note that other types and sizes of lumber may also be used in fabricated timbers, including hardwood, rough-cut wood, or wood of thicknesses less than or greater than about 1.5 inches, etc. The only factor limiting the composition of a fabricated timber 100 is that it should possess certain attributes as described herein below.
[0044] In the example where members 110 , 120 , and 130 are each separate members, one attribute that these members should possess is a common shrinkage characteristic. The term “shrinkage characteristic” as used herein refers to expected amounts and directions of shrinkage over time and/or under particular conditions for a particular material (e.g., wood, etc). Further, should the material from which members (e.g., 110 , 120 , and 130 ) are fabricated include a grain (as with e.g., wood, fiber-cement, etc), the grain of each member should be oriented in substantially the same plane, such as a horizontal plane. Such grain alignment may result in shrinkage over time that is relatively consistent in direction and amount between each of the members. Further, any given member (e.g., 110 , 120 , and 130 ) may actually comprise multiple separate members of various lengths positioned end-to-end resulting in an overall length of l. The term “grain” as used herein typically refers to an overall direction of a pattern of fibers or the like of a material such as that from which members of a fabricated timber are comprised.
[0045] The term “fabricated timber” as used herein refers to a statutory article(s) of manufacture constructed according to various example methods described herein and that is configured for possessing various attributes specified herein. The term “fabricated timber” does not refer to any pre-existing article(s) of manufacture or the like. Nor does it suggest any pre-existing method(s) of construction or the like.
[0046] In one example of a fabricated timber 100 , a vertical member (e.g. 120 ) is disposed atop a horizontal member (e.g., 130 ) such that the outer portion of the vertical member overhangs the horizontal member resulting in a reveal, such as reveal r 140 . Either or both vertical members may be disposed to provide such a reveal r 140 . Such a reveal is typically from 0% up to about 50% of the thickness t v of the vertical member. Such a reveal can be used for, among other things, a location for chinking or the like and/or running wiring, plumbing, and/or other utilities or the like as described below. In one example, a reveal up to ¾ inch (about ¼ inch being preferred) is provided for chinking or the like. The term “reveal” as used herein typically refers to a side of an opening between an outer surface and an inner surface. An example of such a side of an opening is provided by r 140 with respect to the outer surface of member 120 (opposite F i ) and to the inner surface F o of member 130 .
[0047] In another example of a fabricated timber 100 , a vertical member (e.g. 120 ) is positioned atop a horizontal member (e.g., 130 ) such that no reveal is provided, but such that the outer face of the vertical member is substantially flush with the outer side of the horizontal member instead. Such a “no reveal” configuration may provide for stacked timbers that have an appearance of a square log with a height that is the combined height of the stacked timbers where the horizontal interfaces between the stacked logs are dressed so as to be substantially non-visible. Other “no reveal” configurations are also acceptable, as described below.
[0048] The term “dressed” (“dressing”, “dress”, and the like) as used herein typically indicates treating the outside faces of individual or stacked fabricated timbers and/or interfaces of stacked fabricated timbers to have a desired appearance. For example, it may be desirable for the outside faces of fabricated timbers to have the appearance of a square log, a peeled log, and/or a rough-hewn log, or the like. In one example, the outside faces and/or interfaces of such timbers may be distressed using a chainsaw or the like to produce an appearance of a rough-hewn log. Interfaces may be filled with wood filler or the like to hide them before or after distressing. Such dressing or distressing may be performed prior to timbers being stacked, or after stacking, or both. The term “desired” as used herein typically refers to some quality or characteristic or the like that is expected as a result of some action, design, planning, or the like.
[0049] Other aspects of the term “dressed” as used herein may include staining, tinting, painting, or otherwise coloring, finishing, and/or otherwise treating the faces, visible portions, and/or interfaces of fabricated timbers. Other examples may include sealing and/or waterproofing or the like. Another example may include chinking, such as with conventional chinking, cement, sand mortar, flexible vinyl chinking, or the like. Conventionally, chinking is used to seal gaps between logs. In the case of fabricated timbers, chinking is primarily used for aesthetic reasons and to obtain a conventional chinked appearance or the like.
[0050] Various attributes that a fabricated timber 100 configured for building construction should possess include the capability of sustaining various loads including at least dead loads, live loads, and environmental loads. The noun “building” as used herein typically refers to a structure (generally enclosed by walls and a roof) constructed to provide support and shelter for an intended occupancy. The term “occupancy” as used herein typically refers to the purpose for which a building or other structure, or portion thereof, is used or intended to be used. The term “load” as used herein typically refers to forces or other actions upon a building that result from the weight of building materials and the like, building occupants and/or their possessions, objects supported by the building, environmental effects, differential movement, restrained dimensional changes, and the like. The term “dead loads” as used herein typically refers to substantially permanent loads such as the weight of materials of construction incorporated into a building or structure including but not limited to walls, floors, roofs, ceilings, stairways, built-in partitions, finishes, and all other similarly incorporated construction materials, and all equipment and the like affixed to the building or structure, but not including live loads or environmental loads. In one example, a fabricated timber may be configured to sustain a desired dead load of at least fifteen pounds per square foot. The term “live loads” as used herein typically refers to loads produced by occupancy of a building or structure that do not include dead loads or environmental loads. In one example, a fabricated timber may be configured to support a desired live load of at least thirty pounds per square foot. The term “environmental loads” as used herein typically refers to loads that act on a building or structure as a result of weather, topography, or other natural phenomena including but not limited to wind, snow, rain, ice, seismic activity, temperature variations leading to thermal expansion or the like, ponding, dust, fluids, floods, and lateral pressures from soil, ground water, bulk materials against the building, and the like, but not including dead loads or live loads. In one example, a fabricated timber may be configured to support a desired environmental load of at least ten pounds per square foot. In another example, a fabricated timber may be configured to support at least the desired dead load, live load, and environmental load combined. The term “support” as used herein with respect to a fabricated timbers typically indicates a capability to bear desired loads plus a safety factor without exceeding a yield strength of the fabricated timber or, in other words, while maintaining its elasticity.
[0051] FIG. 2 a is a diagram showing a top view of an example fabricated timber 100 . This top view shows portions of example horizontal member 130 and example vertical members 110 and 120 , as also shown in FIGS. 1 a and 1 b . Also shown in FIG. 2 a are holes (e.g., 220 ) of sufficient diameter to allow tie-down fasteners to pass through horizontal member 130 via the holes, as well as blocking (e.g., 224 ) optionally disposed on one or both sides of each hole. In one example, holes (e.g., 220 ) in the horizontal member are located approximately every m feet on center. The term “every m feet on center” as used herein refers to a hole at least every m feet along the length l of the horizontal member, each such hole approximately centered within the width w of the horizontal member (e.g., 130 ). In another example, holes (e.g., 220 ) may be provided at other increments (e.g., every b units) along the length l of the horizontal member. In other examples, a fabricated timber 100 may be fabricated to include the holes (e.g., 220 ) and optional blocking (e.g., 224 ) as a single member. Note that any blocking (e.g., 224 ) may comprise holes and/or notches (e.g., 225 ) to facilitate utility runs such as wiring, plumbing, etc. Any one block may comprise from one to four corner notches (only one 225 shown in FIG. 2 b ) and/or any number of holes. Generally all blocking in a fabricated timber would comprise the same hole/notch number and pattern. The size of the holes/notches (e.g., 225 ) is typically sufficient for desired runs of wiring, plumbing, and other utilities and the like. Such blocking holes/notches (e.g., 225 ) may alternatively be referred to as “blocking utility ports”.
[0052] FIG. 2 b is a diagram showing an end view of the example fabricated timber 100 . This end view shows portions of example horizontal member 130 and example vertical members 110 and 120 , as also shown in FIGS. 1 a and 1 b . Also shown in FIG. 2 b is an end view of example blocking 224 . The composition of the blocking (e.g., 224 ) is typically the same as that of the fabricated timber's members (e.g., 110 , 120 , and 130 ). Further, should the material from which members 110 , 120 , 130 , and 224 are fabricated include a grain (as with e.g., wood, fiber-cement, etc), the grain of each member, including blocking members (e.g., 224 ), should be oriented in substantially the same plane. Such grain alignment may result in shrinkage over time that is relatively consistent between each of the members. In one example, blocking (e.g., 224 ) is attached to vertical member (e.g., 110 and 120 ) with fasteners (e.g., 226 ) as illustrated in FIG. 2 b . In a particular example, blocking is fastened by installing two nails on each side (e.g., 110 and 120 ), as illustrated. Alternatively or additionally, the fasteners (e.g., 226 ) may be installed on the bottom (e.g., 130 ) and/or through the bottom of a next timber (e.g., FIG. 3 , 330 ), leaving the outer faces of the vertical members free from any appearance of fasteners. In another example, other types or sizes of fasteners may be installed to fasten blocking. Note that the height h of the blocking is substantially the same as the height h of vertical members 110 and 120 . Preferably, the blocking height is not greater than, but may be the same as or somewhat less than the height of the vertical members.
[0053] FIG. 3 is a diagram showing an example wall 300 constructed from a plurality of example fabricated timbers (e.g., 100 i , 100 , and 100 t ). In this example, bottom fabricated timber 100 i is attached atop foundation 310 . Alternatively, the bottom fabricated timber 100 i may be positioned atop any other type of foundation suitable for a building or structure. The term “foundation” as used herein typically refers to the lowest load-bearing portion of a building which may comprise any suitable design and material. In this example, tie-down fasteners (e.g., 312 ) may be embedded in or attached to the foundation using conventional techniques. The tie-down fasteners may be comprised of multiple components (e.g., 312 , 320 , and 322 ) and may continue upward via holes in the horizontal member (e.g., 130 ) of each fabricated timber (e.g., 100 i , 100 , and 100 t , as well as all other fabricated timbers). The term “tie-down fastener” as used herein typically refers to a fastening device or mechanism configured to secure some object(s) (e.g., a fabricated timber(s)) against a base of some kind (e.g., a foundation).
[0054] In one example, bottom fabricated timber 100 i may include an optional additional member (e.g., 316 ) that may be fastened to the top of its horizontal member inside the timber via fasteners (e.g., 314 ) and further attached to the foundation via a nut and washer or the like (e.g, 318 ), thus locking down the bottom fabricated timber 100 i to the foundation.
[0055] Example wall 300 extends upward to the desired height by stacking and attaching fabricated timbers one atop another starting with a bottom fabricated timber (e.g., 100 i ) up through the top fabricated timber (e.g., 100 t ). The fabricated timbers are typically stacked so as to be level horizontally and to be substantially plumb. Such stacking can typically be performed by two or three people (workers) without the use of a crane or other heavy equipment or the like. The holes in the horizontal members may be sufficiently aligned vertically so as to allow tie-down fasteners (e.g., 312 & 320 ) to pass through each stacked fabricated timber while remaining substantially plumb vertically. In one example, the holes are drilled or otherwise formed by the workers as the timbers are stacked. One method of finding the correct location for each hole is to place the next timber in the desired horizontal position above the lower timber and atop the applicable and substantially plumb tie-down fasteners, beat the horizontal member of the next timber against the tops of the tie-down fasteners so as to form discernible marks on its bottom at the locations where the tie-down fasteners touch the horizontal member, and then drill or otherwise form the holes according to the marks. This method typically allows for the holes to be formed by the workers at the required locations along the horizontal member of the next timber at the job site without complex design or measurements or the like.
[0056] Regarding the tie-down fasteners, these fasteners may be attached to or embedded in foundation 310 at their lower ends, that extend through the courses of stacked fabricated timbers forming a wall, and that are fastened to the top of the wall thus maintaining the wall in a high degree of force over time against the foundation (e.g., 310 ). Such tie-down fasteners may be configured to maintain the high degree of force on the wall, even in the event of shrinkage of the wall's fabricated timbers and in the event that various forces are applied to the wall, including environmental forces such as wind, earthquake, shifting, flooding, and the like.
[0057] In one example, each tie-down fastener may be a threaded rod, or a plurality of threaded rods (e.g., 320 ) coupled together by coupler nuts (e.g., 322 ). A bottom rod, also known as an anchor bolt, (e.g., 312 ) may be embedded in or otherwise attached to the building's foundation (e.g., 310 ) via conventional means. The bottom rod may be sufficiently long to pass through the first course of fabricated timbers (e.g., 100 i ) and may be coupled via a coupling nut (e.g., 322 ) or the like to a second rod (e.g., 320 ) that is sufficiently long to pass through at least a second course of fabricated timbers, etc., until a final rod or top portion of a single rod passes into and/or through a top fabricated timber (e.g., 100 t ). In one example, a tie-down fastener and related components may terminate against the horizontal member of the top fabricated timber. In another example, wall cap members 332 and 334 may cap the final course of fabricated timbers and allow for the tie-down fastener(s) to hold the stacked courses of fabricated timbers against the building foundation (e.g., 310 ). Member 332 may be optional. Member 334 may be the same width as a horizontal member (e.g., 130 ) or extend up to the entire width of a fabricated timber (e.g., 100 t ). The desired holding force may be achieved via a tensioner mechanism (e.g., 333 ) such as a spring or the like positioned atop a washer or plate (e.g., 331 ) locked in position via the rod (e.g., 320 ) by a nut (e.g., 336 ) and washer (e.g., 335 ) or other suitable locking device(s). Any other suitable tensioner mechanism may alternatively/additionally be used to provide the desired force on the wall 300 . In one example (not illustrated), the tensioner mechanism may be installed on top of wall top cap (e.g., 332 and 334 ). In another example, the tensioner mechanism may be installed inside the top fabricated timber 100 t against its horizontal member as illustrated in FIG. 3 . In one example of a wall constructed using fabricated timbers, the tie-down fasteners comprise threaded metal rods (e.g., 320 ) ⅝ inches in diameter joined by coupler nuts (e.g., 322 ) as needed, the bottom rods or anchor bolts (e.g., 312 ) embedded at least 6 inches in a conventional concrete foundation (e.g., 310 ), the tie-down fasteners spaced at least every 4 feet along the horizontal length of the wall (e.g., 300 ), with the top ends attached via tensioner mechanisms (e.g., 333 ) and associated components (e.g., 331 , 335 , and 336 ), and where each combination of tie-down fastener, tensioner mechanism, and associated components (e.g., 331 , 335 , and 336 ) has a tension capacity of at least 2,500 lbs. The term “tension capacity” as used herein is related to a material's or object(s)'s “tensile strength” and indicates a rated usage value below such a tensile strength. The term “associated components” as used herein typically refers to various pieces of hardware or the like required to complete, secure, and/or retain a tie-down fastener and/or tensioner mechanism, pieces of hardware such as washers, plates, nuts, pins, and the like.
[0058] Each course of fabricated timbers of a wall is typically attached to the previous course. FIG. 3 shows an example of how one course can be attached to the previous course. In this example, fasteners (e.g., 328 and 330 ) are installed to attach a next fabricated timber that is being stacked atop a previously stacked fabricated timber. Fasteners (e.g., 328 ) are installed so as to attach the horizontal member of the next fabricated timber to the vertical members (e.g., 110 and 120 ) of the previous fabricated timber (e.g., 110 ). Further, additional fasteners (e.g., 330 ) may be installed so as to attach the horizontal member of the next fabricated timber to some or all of the blocking (e.g., 224 ) of the previous fabricated timber (e.g., 110 ).
[0059] Prior to attaching a next fabricated timber to the previous fabricated timber, gaps and the like between the two may be substantially removed. In one example, this is done by compressing the next fabricated timber against the previous fabricated timber sufficient to remove such gaps. Such may be accomplished using existing tie-down fasteners to force the next fabricated timber toward the foundation until gaps and the like between the next fabricated timber and the previous fabricated timber are substantially eliminated. Given a threaded rod tie-down fastener, a plate or the like may be slid down the rod against the top of the next fabricated timber, and a nut tightened against the plate to remove any gaps. Then, while under compression with gaps substantially removed, the next fabricated timber may be attached to the previous fabricated timber.
[0060] As one fabricated timber is stacked atop another, one or more beads of caulking and/or glue or the like may be applied. In one example, a bead of caulking may be applied along the length of a top of a fabricated timber's vertical members (e.g., 110 and 120 ) prior to stacking another fabricated timber on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is configured to remain flexible over time, though cycles of hot and cold seasons, and to seal out moisture, bugs, air, and/or other substances and/or objects, and be further configured to maintain such a seal given settling, movement, shrinkage, or the like of the fabricated timbers. Another such bead may be similarly applied that is formed of glue or construction adhesive or the like.
[0061] A wall constructed of fabricated timbers that supports angled trusses may also include weight distribution members that typically approximate the shape of a right triangle, as illustrated in FIG. 3 by element 340 . In one example, one such weight distribution member (e.g., 340 ) is installed atop the wall (e.g., 300 ) under each truss (e.g., 338 ). Each such weight distribution member is typically disposed and configured to evenly distribute the various loads imposed by the truss across the top surface of the top course of fabricated timbers (e.g., 100 t ). The width of such a weight distribution member is typically about the same as the width of the wall top cap or the like that it is disposed upon. The height and hypotenuse of the weight distribution member are typically configured to support the truss by contact along the length of the hypotenuse. Such a weight distribution member may be fabricated any of the materials suitable for members of a fabricated timber.
[0062] FIG. 4 is a diagram showing an example method 400 for constructing a fabricated timber. Such timbers may be partially or completely assembled as pre-manufactured timbers off-site at a factory or the like, or they may be partially or entirely assembled on-site. In both cases, the basic process of construction is typically the same.
[0063] Block 402 typically indicates determining a total desired load plus a safety factor that the fabricated timber should support without exceeding its yield strength. The total desired load may be a minimum, and is typically comprised of a determined desired minimum dead load (block 410 ) plus a determined desired minimum live load (block 420 ) plus a determined desired minimum environmental load (block 430 ). Each of these determined loads may be based at least on the overall design, occupancy, and physical environment of the building. Alternatively, desired average, maximum, or other loads may be used instead of desired minimum loads.
[0064] Block 440 typically indicates determining a composition of each of the various members of the fabricated timber. Such determining may be based at least on the determined desired loads (e.g., block 402 ) and aspects of the design, occupancy, and physical environment of the building comprising the fabricated timber. Such determining may also take into account a desired outside dressing and/or desired inside dressing of the fabricated timber. Note that the various members of a fabricated timber need not be of the same composition. Nor need one fabricated timber (or various members thereof) used in a building be of the same composition as another fabricated timber (or various members thereof) used in the building.
[0065] Block 440 also typically indicates determining a thickness of the various members of the fabricated timber, such as members 110 , 120 , 130 , and 224 . Such determining may be based at least on the determined desired loads (e.g., block 402 ) and aspects of the design, occupancy, and physical environment of the building comprising the fabricated timber. Such determining may also take into account a desired outside dressing and/or desired inside dressing of the fabricated timber. Note that the various members of a fabricated timber need not be of the same thickness. Nor need one fabricated timber (or various members thereof) used in a building be of the same thickness as another fabricated timber (or various members thereof) used in the building.
[0066] The end result of the determinings indicated by block 440 is generally that the compositions and thicknesses of the various members of the fabricated timber have been determined. Another aspect (not explicitly indicated in FIG. 4 ) is determining the length of the fabricated timber or each of the fabricated timbers used in a building or wall or the like. Generally the length of each fabricated timber is based upon it position in a wall of a building or the like, the position of windows, doors, and other opening, the length of the wall, etc. A typical fabricated timber may generally be between approximately one and thirty feet in length. Should a wall require greater lengths, two or more such fabricated timbers may be disposed end-to-end to obtain the desired overall length. Yet another aspect (not explicitly indicated in FIG. 4 ) is determining the width of the horizontal member and the height of the vertical members of the fabricated timber or of each of the fabricated timbers used in a building or wall or the like. The width may be determined based on a desired thickness of a wall or portion thereof. The desired thickness may be based on a desired amount of insulating value, a desired appearance, or other factors that may impact the width of a wall or portion thereof. The desired height may be determined based on a desired timber height, desired appearance, desired locations of windows and/or other openings, desired wall heights, roof heights, and floor heights (such as in multi-level structures), and the like.
[0067] Block 442 typically indicates various aspects of constructing a fabricated timber. Block 450 typically indicates disposing a first vertical member atop a horizontal member. In one example, the first vertical member 110 is typically disposed length-wise atop the left side L (or the right side R) of horizontal member 130 , as illustrated in FIG. 1 b . The first vertical member may be disposed to provide a reveal r 140 , as illustrated in FIG. 1 b . The first vertical member 110 may be fastened to the horizontal member 130 using fasteners installed every n inches on center or the like, and/or the horizontal member and the first vertical member may be fabricated as a single piece. The disposing of the first vertical member atop the horizontal member may take place at a job site as part of the construction of a wall of a building, or as part of a process of construction a plurality of fabricated timbers such as for later use in constructing walls or the like.
[0068] Block 460 typically indicates disposing a second vertical member atop a horizontal member. In one example, the second vertical member 110 is typically disposed length-wise atop the right side R (or the left side L, whichever side the first vertical member is not disposed on), of horizontal member 130 , as illustrated in FIG. 1 b . The second vertical member may be disposed to provide a reveal r 140 , as illustrated in FIG. 1 b . The second vertical member 110 may be fastened to the horizontal member 130 using fasteners installed every n inches on center or the like, and/or the horizontal member and the second vertical member may be fabricated as a single piece. The disposing of the second vertical member atop the horizontal member may take place at a job site as part of construction of a wall of a building or the like, or as part of a process of construction a plurality of fabricated timbers for later use at another site in constructing walls or the like.
[0069] Block 470 typically indicates forming one or more holes in a horizontal member of a fabricated timber. In one example, each hole is formed so as to enable a tie-down fastener to pass through the fabricated timber via the hole. As fabricated timbers are stacked to form a wall, holes formed in each timber are typically aligned with holes formed in any timbers above and below such that a tie-down fastener can to pass through each set of aligned holes in a substantially vertical orientation, as partially illustrated in FIG. 3 . Such holes may be formed off-site during timber fabrication in advance of wall construction, or as part of wall construction at a job site (the location of building construction). Holes are typically formed to allow for tie-down fasteners to be installed at approximately two foot or greater intervals along the length of a wall constructed of fabricated timbers. In one example, holes are formed to allow for a tie-down fastener to be installed at approximately four foot intervals along the length of a wall.
[0070] Block 480 typically indicates installing a fabricated timber's blocking. One example of such blocking is illustrated in FIG. 2 a wherein a block is optionally installed on one or both sides of a formed hole. In one example, a block is installed about two to six inches on one or both sides of a formed hole's center. Such optional blocking is typically installed in each timber such that, when stacked, the blocking of the stacked timbers is substantially aligned vertically. That is, the optional hole blocking of one timber tends to be vertically aligned with that of any timbers above and/or below it. In another example, blocking may additionally or alternatively be installed at intervals unrelated to the location of formed holes. Such blocking of stacked timbers may be installed so as to be substantially aligned vertically. As with forming holes, blocking may be installed off-site during timber fabrication in advance of wall construction, or as part of wall construction at a job site.
[0071] FIG. 5 is a diagram showing an example method 500 for constructing a wall from fabricated timbers. Block 510 typically indicates attaching a timber used in constructing the wall. In one example, the first or bottom fabricated timber of a wall is typically attached to a foundation as described in connection with at least FIG. 3 , elements 100 i and 316 . In another example, a fabricated timber that is stacked upon another fabricated timber is attached as described in connection with at least FIG. 3 , element 328 . Further, holes are typically formed in fabricated timbers so as to enable tie-down fasteners to pass through the fabricated timber via the holes.
[0072] Further, one or more beads of caulking or glue or the like may be applied as a part of the attaching. In one example, a bead of caulking may be applied along the length of a top of a fabricated timber's vertical members (e.g., 110 and 120 ) prior to stacking another fabricated timber on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is designed to remain flexible over time, cycles of hot and cold, and to seal out moisture, bugs, air, and or other substances and/or objects, and be further designed to maintain a seal given settling, movement, and/or shrinkage of the fabricated timbers. Another such bead may be formed from glue or construction adhesive or the like.
[0073] Block 520 typically indicates optionally extending a tie-down fastener(s) to pass through a next fabricated timber used to construct the wall. In one example, tie-down fasteners may be extended as described in connection with FIG. 3 , elements 320 and 322 . In another example, a tie-down fastener(s) may not require extending, such as in the case of using full wall height tie-down fasteners.
[0074] Block 530 typically indicates optionally installing utilities such as electrical wires, gas and/or water lines, ducting, and the like. In one example, electrical wires, water lines, gas lines, ducting, etc, may be run horizontally through the channel ( FIG. 1 a , 180 ) formed by a fabricated timber. Such may require forming holes/notches (e.g., 225 ) in blocking of the fabricated timber(s) to allow the utilities to pass through. In another example, electrical wires, water lines, gas lines, ducting, etc, may also be run vertically from one course of fabricated timbers to another. Such may require forming hole(s) in a horizontal member(s) of the fabricated timber(s) to allow the utilities to pass through. Further, holes may be formed in vertical member(s) of the fabricated timber(s) to allow the utilities to be accesses from the outside surface(s) of the fabricated timber(s). Such holes may be formed to allow for outlets, valves, vents, receptacles, etc.
[0075] Block 540 typically indicates optionally installing insulation. In one example, insulation is installed in the channel ( FIG. 1 a , 180 ) formed by a fabricated timber. Any form of insulation may be installed, or no insulation at all depending on the application of the wall and/or preferences of the builder. Generally, a sufficient quantity of a particular type of insulation is used to provide an insulation R-value (conventional measure of thermal resistance) sufficient for the purpose and location of the wall.
[0076] Once a particular course of fabricated timbers have been stacked and attached, any desired utilities have been run, and any tie-down fasteners have been installed and/or extended, then that course of fabricated timbers is typically complete and a next course may be attached. Block 550 typically indicates determining if there is at least one additional course to be added to the wall being constructed. If so, method 500 continues again at block 510 . Otherwise method 500 continues at block 560 .
[0077] Block 560 typically indicates installing a wall cap at the top of a fabricated timber-based wall. In one example, a wall cap may be fabricated and installed as described in connection with FIG. 3 , elements 332 , 334 , and 336 . Installing wall caps may include forming holes so as to enable tie-down fasteners to pass through the wall caps via the holes. Further, installing wall caps may include applying a bead(s) of caulking and/or glue or the like along the length of a top of the top fabricated timber's vertical members (e.g., 110 and 120 ) prior to installing a wall cap on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is designed to remain flexible over time, through cycles of hot and cold, and to seal out moisture, bugs, air, and/or other substances and/or objects, and be further designed to maintain a seal given settling, movement, and/or shrinkage of the fabricated timbers and/or wall cap. Another such bead may be similarly applied that is formed of glue or construction adhesive or the like.
[0078] Block 570 typically indicates installing tensioner mechanisms to any tie-down fasteners. In one example, such may be installed inside a fabricated timber. In another example, such may be installed on wall caps at the top of a wall.
[0079] Block 580 typically indicates optionally installing chinking in any reveals of the constructed wall, such as reveal 140 of FIG. 1 a that may be provided by fabricated timbers of the wall. Such chinking may comprise material that is intended to be functional and/or decorative in nature. Conventional chinking materials may be used, and/or other non-conventional chinking materials. For example, mortar, stucco, caulk, grout, and/or the like may be used for chinking. Any such materials may be applied using conventional means. In one example, wire mesh may be installed in the reveal area and the chinking material applied over the installed wire mesh. In another example, chinking material may be applied directly to the reveal areas of the stacked fabricated timbers. In another example, electrical wiring may be run along the reveal areas, nail guards installed to protect the electrical wiring, and chinking installed over the nail guard with or without wire mesh.
[0080] FIG. 6 a is a diagram showing an end view 600 a of an example alternate fabricated timber with a 3-dimensional view 600 b of the same example alternate fabricated timber illustrated in FIG. 6 b . Such a timber according to this example is typically fabricated in a similar manner to that of example fabricated timber of FIGS. 1 a and 1 b , with the additional of top horizontal member 190 that may have similar properties, attributes, uses, and characteristics to those of bottom horizontal timber 130 . Further, such a timber according to this example can be used in conjunction with fabricated timbers (e.g., 100 ). In one example, alternate fabricated timbers (e.g., 600 ) may be used for the outside walls of a building while fabricated timbers (e.g., 100 ) may be used for inside walls of the same building. The two types of timbers may even both be used in the same wall. Other combinations of the two timbers are also acceptable. Regarding construction of an alternate fabricated timber (e.g., 600 ), top horizontal member 190 may be attached to the tops of vertical members 110 and 120 in a manner similar to that of bottom horizontal member 130 .
[0081] Alternate fabricated timbers (e.g., 600 ) may be fabricated to be insulated and fully enclosed either at a fabrication site or on a job site. Holes for tie-down fasteners may also be formed either at the fabrication site or on the job site. Blocking may be used to enclose the ends of an alternate fabricated timber, and may be built in at approximately two foot or greater intervals along the length of the timber. Blocking in both fabricated timbers and alternate fabricated timbers may also include holes configured to provide runs for utilities along the length of the inside of alternate fabricated timbers. An alternate fabricated timber may include conduit(s) installed in one or more sets of utility holes in the blocking, the conduit(s) typically extending from one end of the timber to the other. Such conduits may be used to run utilities through alternate fabricated timbers. Blocking in alternate fabricated timbers need not be included on either side of holes formed for tie-down fasteners. Further, horizontal members 130 and/or 190 may include channels or grooves along the length of their outer faces (not shown), the channels configured to provide a run for electrical wiring or the like.
[0082] FIG. 7 is a diagram showing an example wall 700 constructed from a plurality of example alternate fabricated timbers (e.g., 600 ). Like reference numbers refer to like elements within FIG. 7 and between figures. Wall 700 is constructed in much the same way as wall 300 , with some variations to account for the use of alternate fabricated timbers (e.g., 600 ) versus fabricated timbers (e.g., 100 ). One variation may be how one course of alternate fabricated timbers is attached to another course. In one example, strapping 720 is run along adjoining reveals of two stacked courses of alternate fabricated timbers and attached with fasteners 710 at regular intervals, such as approximately every twenty-four inches. Strapping 720 may be formed of solid or perforated metal or the like configured for using nails or the like as fasteners 710 . Alternatively, strapping 720 may be formed of various sized plates or the like, or of construction tape or the like with adhesive or the like performing the function of fasteners 710 . In another example, individual brackets or the like may be used at intervals along the length of courses. Other mechanisms may alternatively and/or additionally be utilized to lock one course to another course when using alternate fabricated timbers.
[0083] In one example, the tensioner mechanism and related components may be installed on top of the wall top cap. In another example, the tensioner mechanism may be installed inside the top fabricated timber 600 t against its bottom horizontal member.
[0084] Another variation may be how blocking is locked into place in an alternate fabricated timber. In one example, blocking in alternate fabricated timbers may be installed at four-foot or less intervals. Fasteners may be installed via the top and bottom horizontal members of an alternate fabricated timber as opposed to via the vertical members. This approach has the advantage of fasteners not being visible on the outside vertical faces of an alternate fabricated timber.
[0085] Another variation may be how a tensioner mechanism and related components are configured. In one example, a plate 733 or the like may be used in conjunction with a tensioner mechanism and a washer 335 and nut 336 . Plate 335 is typically configured to distribute forces from any tensioner mechanism(s) (e.g., 734 ) down the vertical members of alternate fabricated timbers to the foundation. Plate 335 may be made of metal or any other material configured to provide the required force distribution. In one example, plate 335 is a steel plate between ⅛″ and ½″ in thickness that extends substantially across the width of the mating surface of the bottom horizontal member. In another example, plate 335 may alternatively be formed of angle iron or the like, or I-beam or channel or the like.
[0086] Other variations may also include how a bottom course of alternate fabricated timbers is attached to a foundation, how a tie-down fastener is attached to an alternate fabricated timber, etc. Further, alternate fabricated timbers (e.g., 600 ) may be used in combination with fabricated timbers (e.g., FIG. 3 , 100 ). In one example, regular fabricated timbers (e.g., FIG. 3 , 100 ) may be used against a foundation as described in connection with FIG. 3 , 100 i , and a top horizontal member may optionally be added. In another example, regular fabricated timbers (e.g., FIG. 3 , 100 ) may be used for a top course along with regular wall cap members (e.g., FIG. 3 , 332 / 334 ). In another example, a member (e.g., 714 ) similar to a horizontal member of a fabricated timber may be disposed atop the foundation (e.g., 310 ) and a first alternate fabricated timber be stacked and attached atop the member (e.g., 714 ). In one example, such a member (e.g., 714 ) may be made of pressure-treated 2 × lumber or the like. Such a configuration may provide a reveal at as bottom course that is consistent in depth and height with that resulting from two alternate fabricated timbers stacked one atop the other.
[0087] Solid tall wood timbers tend to be very expensive because old growth trees of sufficient size are scarce. Therefore, tall timbers tend to be desirable. FIG. 8 illustrates an example of construction of a tall fabricated timber that has the appearance of an expensive solid tall wood timber. Such a tall fabricated timber may be constructed for use as a fabricated timber (e.g., 100 ) or as an alternate fabricated timber (e.g., 600 ). FIG. 8 illustrates construction of a tall fabricated timber comprising three sections. In one example, section 1 is a fabricated timber (e.g., 100 ). Sections 2 and 3 are tall fabricated timber sections. Section 2 is shown stacked upon and attached (e.g., by fasteners 840 on both sides) to section 1 . Arrows 890 indicates stacking section 3 on section 2 . In one example, as illustrated by section 3 , a tall fabricated timber section comprises vertical members 810 and 820 that are typically formed of the same material as vertical members 110 and 120 . The height of vertical members 810 and 820 need not be the same as that of 110 and 120 . In one example, the base member (e.g., 830+831) of each tall fabricated timber section is typically made of two pieces of 2× lumber attached together as illustrated using any suitable means. Alternatively, the base member may be made of a single piece of lumber or other material. Typically, the base member extends along the length of the section. Such sections may be stacked, compressed, and attached as described elsewhere herein, resulting in a tall fabricated timber. Such a tall fabricated timber may be up to the height of a wall it is used to form.
[0088] FIG. 9 illustrates an example of construction of a single-reveal fabricated timber (e.g., 900 i , 900 , and 900 t ) that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side. Either side may be used on the inside or outside of a building. Such a single-reveal fabricated timber may be constructed in much the same manner as a fabricated timber (e.g., 100 ) and/or an alternate fabricated timber (e.g., 600 ). Vertical member 920 varies from vertical member 120 in that its height is the same as that of the entire timber. Horizontal member 930 varies from horizontal member 130 in that its width is sufficient to provide a desired reveal on one side while the end of the other side abuts the inside bottom face of vertical member 920 such that the bottom face of horizontal member 930 is even with and parallel to the bottom end of vertical member 920 , as illustrated. Such single-reveal fabricated timbers may be stacked, compressed, and attached using fasteners (e.g., 840 ) as described elsewhere herein.
[0089] FIG. 10 illustrates an example of construction of a single-reveal alternate fabricated timber (e.g., 1000 i , 1000 , and 1000 t ) that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side. Either side may be used on the inside or outside of a building. Such a single-reveal alternate fabricated timber may be constructed in much the same manner as a fabricated timber (e.g., 100 ) and/or an alternate fabricated timber (e.g., 600 ). Vertical member 920 varies from vertical member 120 in that its height is the same as that of the entire timber. Top and bottom horizontal members 930 vary from horizontal member 130 in that their width is sufficient to provide a desired reveal on one side while the end of the other side abuts the corresponding inside top or bottom face of vertical member 920 such that the corresponding top or bottom face of horizontal member 930 is even with and parallel to the corresponding top or bottom end of vertical member 920 , as illustrated. Such single-reveal alte4rnate fabricated timbers may be stacked, compressed, and attached using fasteners (e.g., 710 , 720 , and 840 ) as described elsewhere herein.
[0090] FIG. 11 illustrates front and side views of an example fabricated timber end cap (e.g., 1100 ). Such end caps may be attached to exposed ends of wall timbers where the height and width of each end cap is typically equal to the height and width of its corresponding timber end. Any suitable method of attachment may be used, including fasteners such as nails, glue, and/or any others indicated herein and/or the like. Each end cap may be beveled, as illustrated, or otherwise shaped as desired. Further, such end caps may be dressed, either prior to or after attachment, so as to match the appearance of their timbers and/or to create the appearance of being integral portions of their timbers.
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Techniques for building construction using fabricated timbers. In one example, such timbers are fabricated using conventional 2× (two-by) lumber to produce a square log appearance. These fabricated timbers are stacked to form outside and/or inside walls. The fabricated timbers and walls are configured to sustain desired vertical and lateral loads anticipated of a building such as a cabin, home, garage, barn, office building, or the like. A building constructed using such timbers appears to be built of square logs. Fabricated timber construction, as compared to conventional log or stick-frame construction, provides the appearance of high-quality log construction at a far lower cost, with higher R-values and appraised values, and is also far lower in cost and much simpler than conventional stick-frame construction.
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FIELD OF INVENTION
[0001] The present invention is relates to a batter mix composition with reduced oil absorption, wherein the effective amounts of each ingredient in the composition, for decreasing oil absorption and maintaining crisp texture, is as follows: starch 10 to 20 weight %, gum 0.1 to 0.3 weight % and baking powder 0.5 to 1.5 weight %.
BACKGROUND OF THE INVENTION
[0002] Lipid is one of the main nutritional contents which is an essential physiological energy source, and plays an important nutritional and biochemical role in our body. Also, it is an important factor for determining the taste, scent and texture of the food. However, the excessive ingestion of lipid into our body and increase of calories as a result cause bad effects on health such as obesity, and adult diseases. In Korea, the incidence of chronic degenerative diseases and adult disease including cardiovascular disease such as arteriosclerosis and coronary-artery disease, diabetes and obesity is rapidly increasing. This increase is due to the increased consumption of meat and high fat diet caused by the rapid economic growth and westernised dietary habits. Accordingly, the World Health Organisation (WHO) has advised that the lipid intake should be 30% of total calories taken, and saturated fat should not be over 10%. As the governmental policy recommending less lipid intake of the nation is being sought for, it is also necessary for the food industry to actively develop and research low fat/calorie food in accordance to the policy.
[0003] Deep frying is a traditional cooking method which is being used widely in homes, restaurant business and food industry. It is also called as art of cooking process as it provides crispy texture, spicy fragrance, and flavour. Also, deep frying uses high temperature of edible fat and oil (150-200° C.) to heat food. Therefore the heat is conveyed to the food from the edible fat and oil which is the heating medium, and the temperature of the surface is rapidly increased. Then the moisture from the food evaporates and the oil and fat transfers into the food leaving the surface of the food dry to form a hard crust. These processes result in sitological phenomena such as gelatinisation, caramelisation, fat oxidation and mass transport. However, deep fried food is a representative high calorie and high fat food which contains large amount of lipid. Furthermore, approximately 50% of the gross weight is lipid within the deep fried food. Likewise, the excessive intake of high fat/calorie deep fried food may not be beneficial for the consumers' health due to the large amount of oil and fat absorbed into the food during the process. Also, due to the requirement of nutritional indication on food including total fat, content of trans- fat, deep fried food may not be favoured by the consumers affecting the related industry.
[0004] Especially, in Korean homes, deep fried foods are mostly made by frying after mixing the food with batter mix. For example, batter mix is used for cooking chicken according to Korean Patent No 10-0473186 and Korean Patent No 10-0473185 and more. Especially, the Korean Patent No 10-0744830, “Batter mix composition for cheese patty and the manufacturing method of cheese patty employing same”, describes a batter mix composition composed of rice powder, gluten, isolated soy protein and dried albumin so that the batter used for cooking did not burst out maintaining its structure during the heat treatment and the expansion of the cheese. Also, the adhesivity of the batter to the cheese was good so that the cheese could be used directly as a patty, maintaining the taste and scent of the cheese.
[0005] However, so far the utility of the batter mix has been focused on the aspect of flavour and taste of the food. Research on batter mix with reduced oil absorption is limited, and there are no products in the market at present.
[0006] Furthermore, as the physical characteristics of the batter mix affect the customers taste, it is required to develop a batter mix with reduced oil absorption without causing any difference in the quality of the final product.
[0007] The inventors of the present invention performed research in order to produce batter mix with reduced oil absorption properties. As a result they described that corn starch, gellan Gum, and baking powder were effective in reducing the oil absorption within the batter mix composition, and produced the batter mix using the mentioned materials without affecting the taste. Finally, the optimum condition for minimising any changes of the taste was applied to complete the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Technical Task
[0008] Therefore the aim of the present invention was to provide a batter mix composition which is characterised by reducing the absorption of oil during deep frying and also maintains the crispy texture of the final fried product.
Technical Solution
[0009] The aim of the present invention was achieved by selecting gellan gum and baking powder for the batter mix composition that is effective for decreased oil absorption; selecting corn starch for adjusting the quality of the batter in order to show crispy texture; confirming that the oil absorption and the crispy texture of the fried food that has been manufactured using the mentioned batter mix composition has decreased and preserved respectively, referring to the measurement of oil absorption, viscosity and pick up value.
[0000] The present invention provides a batter mix composition containing the effective dose of starch, gums and baking powder.
[0010] “Batter mix” in the present invention, is a mixed powder formed material used for the batter for fried food, and in general the batter mix is composed of flour and additives. In the present invention, weak flour and additives such as corn powder, garlic powder, onion powder, pepper powder and vitamin B were used. Therefore, the batter mix described in the present invention indicates a mixture of weak flour and additives such as corn powder, garlic powder onion powder, pepper powder and vitamin B2.
[0011] “Effective dose” in the present invention, indicates the optimum amount which is used to cook the food using the batter mix composition which shows reduced oil absorption and crispy texture.
[0012] According to the present invention, as the amount of starch decreases, the oil content increases, but the viscosity and pick up value decreases. However, when the amount of starch increases, the oil content decreases but the viscosity and pick up value increases. When the amount of gums and baking powder decreases, the oil content decreases but the viscosity and pick up value increases. However, when the amount of gums and baking powder increases, the oil content increases but the viscosity and pick up value decreases.
[0013] Therefore, the composition of the batter mix is added with additives at their effective dose for making the final fried product which shows reduced oil absorption and crispy texture. Preferably, 10-20 weight percentage (%) of starch, 0.1-0.3 weight percentage (%) of gums and 0.5-1.5 weight percentage (%) of baking powder are added to the composition.
[0014] The mentioned starch in the present invention is used by choosing one or mixing two types of starches among corn starch, sweet potato starch, tapioca starch, and rice powder. However, the selection is not only limited to these, and other types of starches known in the field can be used.
[0015] The mentioned gums in the present invention is used by choosing one or mixing two types of gums among gellan gum, guar gum, and locust bean gum. However, the selection is not only limited to these, and other types of gums known in the field can be used.
Effects of the Invention
[0016] The batter mix composition described in the present invention which is manufactured by mixing the effective doses of selected starch, gum, and baking powder, is useful for improving people's health and related food and the food service industry. The batter mix composition allows reduction of oil absorption and minimise the change of taste during deep frying, and therefore, producing various deep fried food with less fat and improved taste.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a graph showing the oil content of the batter added with different amounts of gellan gum.
[0018] FIG. 2 is a graph showing the viscosity of the batter added with different amounts of gellan gum.
[0019] FIG. 3 is a graph showing the pick up value of the batter added with different amounts of gellan gum.
[0020] FIG. 4 is a graph showing the oil content of the batter added with different amounts of corn starch.
[0021] FIG. 5 is a graph showing the viscosity of the batter added with different amounts of corn starch.
[0022] FIG. 6 is a graph showing the pick up value of the batter added with different amounts of corn starch.
[0023] FIG. 7 is a graph showing the oil content of the batter added with different amounts of gellan gum and corn starch.
[0024] FIG. 8 is a graph showing the viscosity of the batter added with different amounts of gellan gum and corn starch.
[0025] FIG. 9 is a graph showing the pick up value of the batter added with different amounts of gellan gum and corn starch.
[0026] FIG. 10 is a graph showing the oil content of the batter added with different amounts of baking powder.
[0027] FIG. 11 is a graph comparing the oil content of the control batter with the batter showing reduced oil absorption according to the present invention.
[0028] FIG. 12 is a graph comparing the viscosity of the control batter with the batter showing reduced oil absorption according to the present invention.
[0029] FIG. 13 is a graph comparing the pick up value of the control batter with the batter showing reduced oil absorption according to the present invention.
MODE FOR IMPLEMENTATION OF INVENTION
[0030] The preferred method of implementation of the present invention is described below, referring to the examples in detail. However, the scope of the present invention is not limited to these examples.
EXAMPLE
[0031] The most important finding of the present invention is the selection of the batter mix composition with reduced oil absorption during deep frying which gives crispy texture to the final product. Gellan gum and baking powder was selected to reduce oil absorption and corn starch was selected for maintaining the crispy texture of the batter.
[0032] For the batter mix composition, weak flour and additives such as corn powder, garlic powder, onion powder, pepper powder and vitamin B were used. Also, different amounts of gellan gum, baking powder and corn starch were added to the composition to measure the optimum ratio of composition by measuring the oil content, viscosity and pick up value of the batter.
Example 1
Measurement of Viscosity, Pick Up Value and Oil Content of the Batter After Adding Gellan Gum
[0033] In the present example, the oil content, viscosity and pick up value of the batter was measured after adding different amounts of gellan gum. CJ batter was used as a control. 0.5-2 weight percentage (%) of gellan gum was added to 100 g of batter mix composition mixed with 140 g of water to make the batter. Then the viscosity of the batter mix was measured using bostwick consistometer. Then the pick up value was measured from the sweet potato dipped in the batter which was in a regular form (diameter 60 mm×thickness 4 mm). Also, to measure the oil content, the sweet potato dipped in the batter was fried in soybean oil for 4 minutes and then cooled down for 7 minutes. Then the fried sweet potato was grinded using a mixer within liquid nitrogen and the fat was extracted for 6 hours using the soxhlet extractor using ethyl ether as a solvent.
[0034] Pick up value (%)=weight of the batter attached to the sweet potato/weight of fresh potato×100 Oil content (%=(Wi×Wo)/Wi×100
[0000] Wi: weight of sample before fat extraction, Wo: weight of sample after fat extraction
[0035] The oil content of the deep fried sweet potato added with gellan gum is shown in FIG. 1 . According to FIG. 1 , the oil content of the deep fried sweet potato added with gellan gum was significantly smaller than the control.
[0036] Also, the viscosity of the batter added with gellan gum is shown in FIG. 2 . According to FIG. 2 , adding gellan gum resulted in increased viscosity of the batter (shorter the consistometer distance, bigger the viscosity).
[0037] Also, the pick up value of the batter added with gellan gum is shown in FIG. 3 . According to FIG. 3 , adding gellan gum resulted in increased pick up.
Example 2
Measurement of Viscosity, Pick Up Value and Oil Content of the Batter After Adding Corn Starch
[0038] It has been described in example 1 that adding gellan gum to the batter mix resulted in decreased oil content, but increased viscosity and pick up value. Corn starch was selected to be added to the batter mix to decrease the viscosity while maintaining the decreased oil content. This is due to the fact that the increased viscosity has a negative effect on giving crispy texture to the final product.
[0039] In order to confirm this, various amounts of corn starch ranging from 3 to 9 weight percentage (%) was added to the matter mix to make the batter mix composition. Then the viscosity, pick up value and oil content of the batter was measured using the method described in Example 1.
[0040] The oil content of the deep fried sweet potato after adding corn starch is illustrated in FIG. 4 . As shown in FIG. 4 , the oil contents of the deep fried sweet potato added with corn starch of more than or equal to 6 weight percentage (%), were not very different compared with the control.
[0041] The viscosity of the batter after adding corn starch is illustrated in FIG. 5 . As shown in FIG. 5 , the viscosity of the batter decreased when more corn starch was added (longer the consistometer distance, smaller the viscosity).
[0042] The pick up value of the batter after adding corn starch is illustrated in FIG. 6 . As shown in FIG. 6 , as more corn starch was added to the batter, the pick up value of the batter decreased due to lowered viscosity.
Example 3
Measurement of Viscosity, Pick Up Value and Oil Content of the Batter After Adding a Mixture of Gellan Gum and Corn Starch
[0043] It was described that adding gellan gum to the batter mix resulted in decreased oil absorption, but the viscosity and pick value of the batter had increased which may have had an effect on the crispness of the batter. Therefore, in order to maintain the effect of decreased oil absorption and improve the crispy texture, a mixture of gellan gum and corn starch was added to the batter mix. Then the oil content, viscosity and pick up value of the batter was measured using the methods described in Example 1.
[0044] The oil content of the deep fried sweet potato added with the mixture of gellan gum and corn starch is shown in FIG. 7 . As shown in FIG. 7 , the oil content of the deep fried sweet potato added with the mixture of gellan gum and corn starch was significantly lower than the control.
[0045] The viscosity of the batter added with the mixture of gellan gum and corn starch is shown in FIG. 8 . As shown in FIG. 8 , the viscosity of the batter added with a mixture of corn starch and 1 weight percentage (%) of gellan gum was similar to the control. However, when the mixture of corn starch and 2 weight percentage (%) of gellan gum was added, the viscosity significantly increased compared to the control (shorter the consistometer distance, bigger the viscosity).
[0046] The pick up value of the batter added with a mixture of gellan gum and corn starch is shown in FIG. 9 . As shown in FIG. 9 , the pick up value of the batter added with a mixture of corn starch and 1 weigh percentage (%) of gellan gum was similar to the control. However, when the mixture of corn starch and 2 weight percentage (%) of gellan gum was added, the pick up value significantly increased due to the increased viscosity.
Example 4
Measurement of the Oil Content After Adjusting the Amount of Baking Powder
[0047] Adding baking powder creates pores in the batter during deep frying which could assist the absorption of oil. Therefore, the oil content of the batter after adding different amounts of baking powder was measured using the method described in Example 1.
[0048] The oil content of the deep fried sweet potato made with different amounts of baking powder is illustrated in FIG. 10 . As shown in FIG. 10 , as the amount of baking powder decreases, the oil content also decreases.
Example 5
The comparison of the Oil Content Between an Optimised Batter Mix Composition for Reduced Oil Absorption With Control
[0049] According to the mentioned experiments, an optimised batter mix composition with reduced oil absorption was made by adding the selected 10-20 weight percentage (%) of corn starch, 0.1-0.3 weight percentage (%) of gellan gum, 0.5-1.5 weight percentage (%). The rest that were added to the batter mix composition were 75-85 weight percentage (%) of weak flour, 1-5 weight percentage (%) of additives (Table 1). The oil content, viscosity and pick up value of the batter and the CJ batter (control) were measured to be compared with each other.
[0000]
TABLE 1
The batter mix composition according to the present invention
Material
Mix proportion (weight percentage (%))
Weak flour
75.0-85.0
Corn starch
10.0-20.0
Corn powder
2.0-3.0
Refined salt
1.0-2.0
Baking powder
0.5-1.5
Gellan gum
0.1-0.3
Garlic powder
0.1-0.3
Black pepper powder
0.005-0.015
Vitamin B2
0.001-0.003
Total
100.00
[0050] The oil content of the batter mix composition with reduced oil absorption and CJ batter was measured and illustrated in FIG. 11 . As shown in FIG. 11 , the oil content of the batter mix composition with reduced oil absorption was decreased by 34% compared with the CJ batter.
[0051] The viscosity of the batter mix composition with reduced oil absorption and CJ batter was measured and illustrated in FIG. 12 . FIG. 12 shows that the viscosity of the batter mix composition with reduced oil absorption had decreased compared with the CJ batter.
[0052] The pick up value of the batter mix composition with reduced oil absorption and CJ batter was measured and illustrated in FIG. 13 . As shown in FIG. 13 , the pick up value of the batter mix composition with reduced oil absorption showed decreased pick up value compared with the CJ batter. This is due to the decreased viscosity of the batter mix composition. The results indicate that the batter mix composition absorbs less oil even though the batter is thin around the sweet potato ( FIG. 11 ).
Example 6
Food Taste Testing and Sensory Evaluation of the Deep Fried Sweet Potato Made With the Mentioned Batter Mix
[0053] Food taste testing was performed on the deep fried sweet potato made with the batter mix composition described in Example 5.
[0054] The level of satisfaction after taste testing the deep fried sweet potato was explored among 160 students who were within 20-30 years of age, living in Seoul. The results are shown in Table 2.
[0000]
TABLE 2
Sensory evaluation of consumers. (maximum score is ten)
Control
Batter mix composition with
Preference
(CJ batter)
reduced oil absorption
General preference
5.7
5.7
Chewing (texture) preference
5.1
5.6
Sensibility inside the mouth
5.1
5.4
Crispness preference
5.5
6.0
Degree of crispness
5.3
5.7
Aftertaste preference
5.8
5.8
Off flavour intensity
4.7
4.4
[0055] As shown in Table 2, the preference results of the sensory evaluation test were compared between control and batter mix composition with reduced oil absorption made with corn starch and gellan gum. It shows that the batter mix composition has similar quality preference to the control batter.
[0056] This investigation shows that the batter mix made with corn starch, gellan gum and baking powder satisfies the consumers' appetite. Also it indicates that the batter mix composition with reduced oil absorption may create a new consuming market
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The present invention relates to a batter mix composition with reduced oil absorption, wherein the effective amounts of each ingredient in the composition, for decreasing oil absorption and maintaining crisp texture, is as follows: starch 10 to 20 weight %, gum 0.1 to 0.3 weight % and baking powder 0.5 to 1.5 weight %. The batter mix composition of the present invention is prepared by mixing a selected starch, gum and baking powder in effective amounts. When compared with existing products, the composition of the present invention not only reduces oil absorption during the frying process, but also minimizes degradation of the crisp texture. The present invention allows the production of various fried products having low fat content and improved texture, thereby promoting public health and providing a useful innovation to the food service industry.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This application is in the field of devices used in the oil well drilling industry, for releasably connecting one tubular element to another tubular element or piece of downhole equipment.
2. Background Art
In the drilling, completion, production, servicing, and workover of oil and gas wells, it is often necessary to disconnect the work string from a downhole tool, or from a lower section of work string. The downhole tool might include a fluid production device, a drill motor, or a drill bit, or any other bottom hole assembly which might be lowered into the well bore on a work string. Regardless of the type of downhole tool, selective disconnection from the work string may become necessary.
For instance, the bottom hole assembly in use may become stuck in the well bore to such an extent that it is impossible to remove from the well bore. In that case, the operator usually must selectively part the work string from the bottom hole assembly, and remove the work string from the well. Then, other tools can be run into the well bore for removal of the stuck bottom hole assembly. These other tools might be devices for grappling and pulling on the bottom hole assembly, or for jarring the bottom hole assembly loose, or even for milling the bottom hole assembly away.
It is helpful to have a tubular disconnect device in the work string at the desired disconnect location, to allow a positive and predictable release of the bottom hole assembly from the work string. The disconnect device should be impervious to the stresses and strains generated by the bottom hole assembly, and it should not be subject to inadvertent separation or loosening. The well bore environment also often includes the presence of varying amounts of debris, which is usually borne by the fluid being pumped down through the work string or up through the annulus surrounding the work string. A disconnect device should operate reliably despite the presences of such debris.
Various tubular disconnect devices have been developed over the years to achieve this disconnection of the work string from a downhole tool. Some such tools use locking dogs to lock the work string and the downhole tool together. Others may use a grappling device. In either case, the locking dogs or the grappling device are often held in the lock position by a movable piston, with the piston being held in place by a shear pin. After a ball is dropped through the work string, the piston can be displaced by the buildup of working fluid pressure, shearing the shear pin, with the piston being subsequently moved to a position where the locking dogs or the grappling device are no longer held in the lock position. This allows release of the bottom hole tool from the work string, usually by pulling on the work string. Often, in these tools, the bottom hole tool may generate, or be subject to, significant vibrations. These vibrations are often transmitted through the tool into the shear pin, causing it to fail prematurely, thereby inadvertently releasing the downhole tool from the work string.
Another tool which has been used as a tubular disconnect device utilizes a collet finger, or a plurality of fingers, to hold the tool to the work string. An upper tool body is locked to a lower tool body by a sliding collet, with the collet finger being held in a locking groove on the lower tool body by a contour on a lower extension of the upper tool body. The work string is pulled upwardly, raising the upper tool body against the force of a spring between the upper tool body and the collet. When the upper tool body has raised sufficiently, the collet finger is allowed to spring free of the groove in the lower tool body, thereby releasing the lower tool body from the upper tool body. This tool can be released only when the downhole tool is held in place with sufficient force to allow the necessary overpulling of the upper tool body to compress the spring.
Another known tool has a first set of collet fingers which lock the upper tool body to the lower tool body, with the collet fingers being held in the locked position by the lower skirt of an inner piston. The inner piston is held in attachment to the upper tool body by a spring and a second set of collet fingers. After a ball is dropped through the work string, pressure builds up above the inner piston until an outer piston is displaced upwardly by the same fluid pressure to further compress the spring. Upward displacement of the outer piston allows the second set of collet fingers to release the inner piston from the upper tool body, after which the inner piston is driven downwardly by fluid pressure to release the first set of collet fingers, thereby releasing the lower tool body from the upper tool body. The construction of this tool is complicated and expensive, and its proper function depends upon the spring to withstand the jarring load, to prevent the outer piston from displacing sufficiently to inadvertently release the lower body.
Still another known tool has a main piston which holds a set of locking dogs in place, to lock the upper tool body to the lower tool body, with the main piston being held in place by a ball and detent mechanism. A pilot piston holds the ball in the detent, preventing movement of the main piston, with the pilot piston being held in place by shear pins. Dropping of a ball through the work string and application of fluid pressure above the pilot piston shears the shear pins, allowing the pilot piston to release the ball from the detent, resulting in downward movement of the main piston to release the locking dogs. The jarring and impact of high frequency devices on the work string can impart repetitive impact to the shear pins, ultimately resulting in failure of the shear pins and inadvertent release of the tool. Further, the locking dogs of this tool are positioned in cavities that are open to drilling fluids; the particulates carried by the drilling fluid can pack the locking dog cavities sufficiently to immobilize the locking dogs.
BRIEF SUMMARY OF THE INVENTION
The present invention is a tubular disconnect device which has a collet held in place, relative to an upper body, by a set of outwardly biased collet fingers, or a shear pin and a set of collet fingers. The collet fingers are held in engagement with a groove by a movable piston, thereby preventing the application of any impact or force to the shear pin, where present. The collet holds a set of locking dogs in place, locking the upper body and a lower body together. The piston is biased upwardly away from the collet by a spring. Dropping of a ball through the work string allows application of fluid pressure above the piston, thereby compressing the spring. After sufficient compression of the spring and downward movement of the piston, the collet fingers are released, and the piston abuts the collet. Continued application of fluid pressure pulls the collet fingers out of their groove, and forces the collet downwardly, thereby freeing the locking dogs from engagement with the lower body, releasing the tool.
The collet can be sealed against the tool body to prevent contamination of the dog cavities with particulates in the drilling fluid. An adjustment sleeve can be provided to establish a rigid connection holding all the major body components in place, to prevent displacement during jarring operations. Where the shear pin is present, it maintains the collet in position after release of the collet fingers, until a higher fluid pressure shears the pin, giving the operator a positive indication that release of the tool has been achieved. However, the collet is actually held in place by the collet fingers, preventing application of impact to the shear pin. Since the collet fingers can not be released until the piston contacts the collet, the tool is highly resistant to inadvertent release.
The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a longitudinal section of the apparatus of the present invention, in the run-in configuration;
FIG. 2 is a longitudinal section of the apparatus of the present invention, showing initial displacement of the piston to abut the collet, and release of the collet finger;
FIG. 3 is a longitudinal section of the apparatus of the present invention, showing initial displacement of the collet, to pull the collet finger out of its groove and to shear the shear pin; and
FIG. 4 is a longitudinal section of the apparatus of the present invention, showing further displacement of the collet, to release the locking dog from the dog cavity.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a longitudinal section view of the disconnect device 10 of the present invention, in which a generally cylindrical upper tool body 12 has an upper end provided with threads for attaching the disconnect device 10 to a work string (not shown). The upper tool body 12 has a lower end which is threadedly engaged with the upper end of a generally cylindrical dog housing 14 , which in turn has a lower end which is slidably engaged with the upper end of a generally cylindrical lower body 16 . The terms “upper” and “lower” are used herein to mean essentially “uphole” and “downhole”, respectively. The disconnect device 10 can be used in a horizontal well bore, as well as a vertical well bore. The slidable engagement of the dog housing 14 with the lower body 16 can be by means of splines and grooves, as shown, to provide torsional strength. The lower end of the lower body 16 is provided with threads for attaching the disconnect device 10 to a bottom hole assembly or other downhole tool (not shown).
A transversely movable locking dog 18 is carried in a dog slot 19 in the dog housing 14 . The locking dog 18 is shown engaged with a dog cavity 20 on the interior surface of the lower body 16 , thereby longitudinally locking the dog housing 14 to the lower body 16 . The locking dog 18 is held in forcible engagement with the dog cavity by abutment with a raised contour 24 on the exterior surface of a generally cylindrical slidable collet 22 . One or more collet fingers 26 extend upwardly from the upper end of the collet 22 . A generally cylindrical collet sleeve 28 surrounds the upper end of the collet 22 and the collet fingers 26 . The upper end of the collet sleeve 28 abuts a shoulder on the upper body 12 , and the lower end of the collet sleeve 28 abuts a shoulder on the dog housing 14 , to hold the collet sleeve 28 longitudinally in place.
The upper end of each collet finger 26 has an outward projection which engages a recess 58 on the interior surface of the collet sleeve 28 . The collet fingers 26 can be outwardly biased to ensure that the fingers 26 engage the recess 58 . Forcible engagement of the collet fingers 26 with the recess 58 in the collet sleeve 28 provides the primary means of longitudinally capturing the collet 22 in place relative to the upper body 12 , thereby longitudinally capturing the collet 22 in place relative to the dog housing 14 . One or more shear pins 30 can be provided to pin the collet 22 to the dog housing 14 . Where provided, the shear pins 30 function as means of informing the operator that release of the tool has been achieved, as will be explained further below. Upper collet seals 32 and one or more lower collet seals 34 seal the annular cavity 56 between the collet 22 and the dog housing 14 and lower body 16 against contamination by drilling fluid, which may be laden with particulates.
A generally cylindrical slidable piston 36 is positioned within the upper body 12 , generally above the collet 22 . The slidable piston 36 is shown in its initial position, or run-in Q position, in FIG. 1 . The piston 36 has an outward projection 38 which abuts the upper ends of the collet fingers 26 , to hold the collet fingers 26 in forcible engagement with the recess 58 in the collet sleeve 28 , when the piston 36 is in its initial position. In the condition shown in FIG. 1, the internal bore of the piston 36 is open, allowing the flow of fluids through the piston 36 , and on through the internal bore of the remainder of the disconnect device 10 . A spring 40 is positioned between the piston 36 and the upper end of the collet 22 , to bias the piston 36 upwardly. This initial position of the piston 36 is also its uppermost position, since the outward projection 38 abuts an internal shoulder on the upper end of the collet finger 26 . Further, in this initial position, the lower end 44 of the piston 36 is vertically spaced apart from an internal shoulder 46 on the collet 22 . The upper end 42 of the piston 36 has an internal seat 50 for receiving a ball to be dropped through the work string, as will be explained below.
An adjustment sleeve 48 on the exterior of the disconnect device 10 is threadedly engaged with the exterior surface of the dog housing 14 . The lower end of the adjustment sleeve 48 abuts the upper end of the lower body 16 . When the adjustment sleeve 48 is threaded in the downward direction, it applies downward force against the lower body 16 and upward force against the dog housing 14 . The lower body 16 in turn applies downward pressure against the dog 18 , which then reacts downwardly against the dog slot 19 in the dog housing 14 . Therefore, it can be seen that adjustment of the adjustment sleeve 48 will apply a desired tension to the dog housing 14 , to remove any looseness or slack in the assembled dog housing 14 and lower body 16 . The dog housing 14 is itself threaded to the upper body 12 , so there is no looseness in the major body components of the disconnect device 10 , thereby minimizing the impact which can be imparted to the collet fingers 26 and the shear pin 30 .
An overpressure device 52 , such as a rupture disk, is provided between the internal bore of the lower body 16 and the annular space surrounding the lower body 16 , below the collet 22 . This allows the operator to overpressurize the internal bore to establish a flow path to the annulus. A fluid bypass device 54 , such as a weep valve, is provided between the internal bore of the lower body 16 and the annular space surrounding the lower body 16 , above the lower seal 34 in the lower end of the collet 22 . An enlarged internal diameter in the lower body 16 can be provided adjacent the weep valve 54 to place the weep valve 54 in fluid flow communication with the annular space 56 , between the collet 22 and the dog housing 14 and the lower body 16 , as shown. The weep valve 54 prevents the annular space 56 from overpressurizing and locking the tool against release.
As seen in FIG. 2, when it is desired to release the disconnect device 10 , a ball B is dropped through the work string to seat on the seat 50 at the upper end 42 of the piston 36 . Fluid being pumped through the work string then builds pressure above the piston 36 , driving the piston 36 downwardly and compressing the spring 40 until the lower end 44 of the piston 36 abuts the shoulder 46 on the collet 22 . It can be seen that, at this position of the piston 36 , the outward projection 38 on the piston 36 has moved downwardly away from its abutment with the upper end of the collet finger 26 , thereby releasing the collet finger 26 to be pulled out of engagement with the recess 58 in the collet sleeve 28 . Therefore, at this point, the collet 22 is no longer captured or locked longitudinally relative to the upper body 12 and the dog housing 14 .
As seen in FIG. 3, as the piston 36 is driven further downwardly by hydraulic pressure, abutment of the piston 36 with the collet 22 drives the collet 22 downwardly, pulling the upper ends of the collet fingers 26 out of the recess 58 in the collet sleeve 28 . Recall that the collet fingers 26 were released to be pulled out of the recess 58 by the initial downward movement of the piston 36 , described above. The weep valve 54 allows fluid to escape the annular space 56 as the collet 22 moves downwardly. Simultaneously, the shear pin 30 , when present, is sheared, to give the operator a noticable pressure drop to provide positive indication that the collet 22 has moved downwardly.
As the piston 36 and the collet 22 continue to be driven downwardly by hydraulic pressure, as shown in FIG. 4, the raised external contour 24 on the collet 22 moves below the dog 18 . This releases the dog 18 from forcible engagement with the dog cavity 20 in the lower body 16 . Downward movement of the piston 36 and the collet 22 can continue until an external shoulder 60 on the collet 22 abuts an internal shoulder 62 on the lower body 16 , or until the collet 22 abuts the upper end of the dog 18 . Once the dog 18 has been released from forcible engagement with the dog cavity 20 in the lower body 16 , the upper body 12 and the dog housing 14 are free to move longitudinally relative to the lower body 16 . Therefore, the work string, the upper body 12 , the dog housing 14 , the collet 22 , and the piston 36 can be pulled out of the well bore, leaving the lower body 16 and any equipment attached therebelow in the well. The lower body 16 can be provided with a grappling contour, as shown, to facilitate its removal from the well bore with a grapple.
While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.
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An apparatus for disconnecting a bottom hole assembly from a work string, having an upper tool body, a piston biased away from a slidable collet, locking dogs held in engagement with a lower tool body by the slidable collet, and one or more collet fingers holding the collet in place, relative to the upper body. The piston can be hydraulically displaced against the biasing spring, thereby releasing the collet finger, followed by further displacement of the piston to contact the collet, then displacement of the piston and the collet to release the locking dogs from engagement with the lower tool body. A shear pin in the collet can provide a positive pressure indication of release of the disconnect device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improvement on the current devices installed on mobile vehicles for receiving urine during expulsion. Included is a distinct and improved reservoir for receiving urine and dispensing said urine into a commode while also providing a convenient mounting system for said reservoir.
2. Description of the Prior Art
As today's society has become more mobile it has become commonplace for vehicles to be designed with commodes that can be used while the vehicle is in transport. Commodes can be found in airplanes, boats, buses, trucks, mobile homes, and trains to name a few. While these conveniences have proven to be invaluable assets, the combination has not been without fault. When males expel urine into the standard commodes installed on vehicles, the jostling of the vehicle can lead to a lack of control of the urine's trajectory. The result is that the urine will land on the exterior of the commode, the floor, or the surrounding walls. This is highly unsanitary and unpleasant. Thus a device that would receive all urine expelled by a male in the standing position despite, being jostled, would be a vast improvement on the prior art.
As described earlier, all of the devices for receiving urine on moving vehicles employ the standard seated commode. This design typically resembles a stool with an opening in the seat that is designed to receive human excrement. The only accommodation that exists for the male expulsion of urine in the standing position is that the seat of the commode can typically be lifted so that any urine that is splashed will not land thereon. While this design is adequate for stationary commodes, the bumps and turns of a moving vehicle can cause the user to miss the commode altogether. There are no devices in the prior art that recognize this fault and rectify it. The present invention comes from the realization that a reservoir is needed that is at an elevated level so that these accidents will not occur. The invention can be installed for use with preexisting arrangements at low cost. While there are other reservoir designs for the receipt of urine, most of these designs are for separate units. None of these provide for a permanent mounting system that makes the reservoir readily available to the user of a mobile commode.
U.S. Pat. No. 4,202,058 to Robert W. Anderson and Carlos Witzke U.S. Pat. No. 5,091,998 are for urinals designed for use by a female, particularly those that do not have access to a commode. The similarities to the present invention relate to the use of a urine receptor cup that is attached to a hose by a port for the transport of urine. The cup designs however are distinctly different. The Anderson '058 and Witzke '998 design incorporate a cup that is suited for the female anatomy while the present invention is for the male anatomy. The primary difference is that the port orientation on the cup for these patents are located at a downward angle from the mouth of the cup which accommodates the female anatomy while the present invention consists of a port directly below the mouth of the cup thus being designed to suit the male anatomy. The present invention incorporates a dispensation design on the opposite end of the hose that is readily adaptable to most commodes while the Anderson '058 patent is designed to dispense the urine by a pumping mechanism. The Witzke '998 patent covers only a cup and hose design. Also unique to the present Invention is a mounting system for the cup that makes it possible to mount the present invention immediately next to a commode and to be used either mounted or grasped for use. This design feature is crucial to the present inventions utility in mobile vehicles and is not disclosed in the Anderson '058 patent or the Witzke '998 patent.
The urine conducting apparatus disclosed in U.S. Pat. No. 3,964,111 to Paul R. Packer uses a cup and port design as well. The cup and its mouth are shaped with a curved design intended for the female anatomy and does not incorporate the barrel shaped structure of the present invention. Thus splashing due to jostling will be a far greater risk in the Packer '111 design. The Packer '111 design is for a receptor cup only and has none of the features of the present invention for mounting and adapting for a commode.
U.S. Pat. No. 4,121,306 to Bernard B. Bringman and Des. 357,979 to Oneita A. Evans are for urinals that are attached to a container by a hose. The port-mouth orientation of these inventions is arranged for the male anatomy and this respect more closely resembles the present invention. However, the dispensing design for theses inventions is for the hoses to enter a container where said container incorporates a mounting receptor to hold the end of the hose in place. The present invention on the contrary includes a special design feature that allows the end of the hose to be mounted on the rim of a commode and thus be used permanently with that commode. In addition, neither the Bringman '306 nor Evans '979 patents disclose a means for mounting said cups for repeated usage in mobile vehicles.
U.S. Pat. Des. 213,557 is for a portable bidet that has a basin design that substantially resembles the standard bidet. A hose feeds into two tubes that are connected to both spray nozzles of the bidet. This hose is attached to a fitting that is designed to be mounted on a spout so that water will be fed to the abovementioned nozzles. The fitting is not suited for the mounting system of the present invention and is not meant for the purpose of receiving urine. The interface between the hose and the bidet is greatly different then the present invention and would not be readily adaptable to standard mobile commodes.
Therefore a need exists for a novel and enhanced device for receiving urine on mobile vehicles. Combining these tasks in a single unit would increase efficiency and minimize the use of storage space. In addition, the design should maximize the safety of the user. In this respect, the mountable urine reservoir according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of receiving urine in a mobile vehicle.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of devices for receiving urine now present in the prior art, the present invention provides an improved combination of adaptability and utility, and overcomes the abovementioned disadvantages and drawbacks of the prior art. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved mountable urine reservoir which has all of the advantages of the prior art mentioned heretofore and many novel features that result in a mountable urine reservoir which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in combination thereof.
In furtherance of this objective, the mountable urine reservoir comprises a mount wherein said mount comprises a hole for connection to a wall and further comprises a keeper for a cup. Said cup is attached to a hose the opposite end of which is mountable on a commode for dispensing urine. There has been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
The abovementioned keeper on said mount comprises two L-shaped fingers positioned so that a urine cup having a upper portion that is wider then the space between said fingers will rest in place and can be removed by lifting said cup in a vertical direction. Said fingers will allow the urine cup to rest in place while attached to a hose that passes to a commode.
In an alternate design of the present invention said mount comprises a recess. At the base of said recess is a ridge. Said urine cup comprises a groove in the bottom wherein said groove will receive said ridge when said cup is inserted into said recess. Said ridge thus holds said cup in place by resisting the weight of said cup.
Another feature of the present invention is a dispenser spout that attaches to the opposite end of said hose. Said dispenser comprises a bent open-mouth design that rests permanently on the rim of a commode and dispenses the urine into the bowl of said commode.
The cup of the present invention is uniquely shaped to allow for either of the abovementioned mounting methods. In addition said shape comprises a long barrel to fully accommodate the male anatomy in a manner so that urine will be expelled within the interior portion of said cup and therefore allow no splashing.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved mountable urine reservoir that has all of the advantages of the prior art and none of the disadvantages.
It is another object of the present invention to provide a new and improved mountable urine reservoir that may be easily and efficiently manufactured and marketed.
An even further object of the present invention is to provide a new and improved mountable urine reservoir that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such mountable urine reservoir economically available to the buying public.
Still another object of the present invention is to provide a new mountable urine reservoir that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a left perspective view of the first preferred embodiment of the mountable urine reservoir of the present invention.
FIG. 2 is a right perspective view of the second preferred embodiment of the mountable urine reservoir of the present invention.
FIG. 3 is a sectional side view of the mounted cup portion of the second preferred embodiment of the mountable urine reservoir of the present invention.
FIG. 4 is a sectional side view of the dispenser spout of the mountable urine reservoir of the present invention wherein the dispensing end rests on a commode. The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1-5 , a preferred embodiment of the mountable urine reservoir of the present invention is shown and generally designated by the reference numeral 10 .
In FIG. 1 is a rectangular wall mount 12 comprising four holes 14 passing through the four corners of said mount 12 wherein the diameter of said holes 14 are sized to receive standard fasteners 16 such as screws, bolts, or nails. Said fasteners 16 will pass through said holes 14 and the heads of said fasteners will lie flush against the exterior surface of said mount 12 . The remainder of said fasteners penetrates a wall and is firmly attached therein. In the first alternative of the preferred embodiment said mount 12 comprises a recess 18 located in the central portion of the face of said mount 12 . Said recess 18 comprises a flat bottom edge and a curved upper edge. The dimensions of said recess 18 is such that a urine reservoir 20 will fit within said recess and rest therein. A hole in the wall would be cut to snugly receive said recess 18 so that the outer portion of said mount 12 remains flush against the wall for mounting by the abovementioned fasteners 16 . Said mount 12 can be made of any variety of lightweight easily molded material such as wood, plastic or metal. Many ornamental shapes can be incorporated.
Also pictured in FIG. 1 is a urine reservoir 20 that comprises a rectangular cup. Said cup comprises a mouth 22 wherein said mouth further comprises a sectional area that is great enough to receive the male penis. Said cup further comprises a rectangular barrel comprising a length great enough to receive a penis while not contacting the walls of said reservoir 20 . The bottom portion of said reservoir 20 comprises a port 24 wherein said port is attached to a hose 26 . Said bottom portion also narrows to a smaller sectional area so that said reservoir 20 acts as a funnel to said port 24 . Said cup 20 would be made of a plastic material that could be easily cleaned and replaced by a new cup.
Connected between said reservoir 20 and a commode is a hose 26 . The upper end of said hose 26 is attached to the bottom portion of said reservoir 20 . The lower portion of said hose 26 passes beneath the seat of a commode and above the rim of said commode. Said lower portion is attached to a dispenser spout 28 . Said spout 28 hangs over the edge of said rim and has an oval shaped mouth 32 . The upper portion of said spout 28 comprises an inlet tube 30 that is attached to said hose 26 and passes into said oval shaped mouth 32 . As urine exits said hose 26 it enters said inlet tube 30 and passes out of said mouth 32 of said spout into the bowl of the commode. Said hose 26 can be made of rubber and should have ample length to reach from a commode and the neighboring wall.
In FIG. 2 the alternate design for said mount 34 is pictured. In this design said mount 34 comprises a rectangular plate wherein said plate comprises four holes 14 located at each of the four corners and has a diameter sized to receive a fastener 16 such as a screw, bolt, or nail. Like the previous design, said fasteners 16 would pass through said holes 14 and penetrate a wall. The head of said fasteners lies flush against said mount 34 and holds said mount 34 in place. Attached to the external face of said mount 34 is a pair of L-shaped fingers 36 wherein one end is attached to said face of said mount 34 and the other ends are positioned opposite of one another. Said fingers 36 are positioned close enough so that said reservoir cup 20 having the same design described above will pass through the space between said fingers 36 at its narrower bottom portion and the wider upper portion will rest frictionally between said fingers 36 . Thus the user can lift said reservoir 20 upwardly to remove it from the mount and can reinsert it for remount. Several other bracket designs can be incorporated as long as they can facilitate ready removal and insertion. Said mount and fingers can be made of plastic, metal or wood.
The remaining design is substantially the same as that of the first alternative. The only difference is that no groove 38 would be necessary in the bottom of said reservoir. This design allows the user to install the present invention without cutting to accommodate said recess 18 . The hose and dispenser spout arrangement of the second alternative is identical to the arrangement of the first alternative.
The sectional view of FIG. 3 is a side view of the mounting plate and reservoir arrangement of the first alternative for the preferred embodiment. The Upper and bottom portions illustrate a sectional view of the face portion of said mount 12 wherein said face comprises a hole for receiving a fastener 16 which penetrates a wall and firmly couples said mount 12 to said wall. The middle portion is a recess 18 wherein the upper and lower walls of said recess 18 are attached to said face and are perpendicular thereto. Said recess 18 comprises a back wall which is attached to said upper and lower walls. Attached to the point of connection between said lower wall and said face is a ridge 40 . The installation of this embodiment would require that a hole be cut in said wall so that said recess 18 would fit within it, but said face would overlap said wall for mounting. A template could be included with the present invention to allow the user to make a exact outline of the desired shape to fit said recess 18 .
The back wall of said reservoir 20 comprises flat surface that has a length that is slightly smaller then the length of said back wall of said recess 20 . The bottom portion of said reservoir 20 comprises a groove 38 adjacent to the rear portion. Said groove 38 is shaped to receive said ridge 40 on said lower wall of said recess 18 and to hold said reservoir 20 in place in a resting position. Attached to the front portion of the bottom of said reservoir 20 is a port. Said port is cylindrical and has an outer diameter that is slightly larger then the inner diameter of said hose 26 so that said hose 26 can be stretched to snuggly fit over said port 24 . The front side of said reservoir 20 curves forward to define an upper mouth 22 that is wider then the lower portion of said reservoir 20 . The upper edge of said front wall is shorter then said rear wall Thus the mouth 22 of said reservoir 20 slants forward. The angle of this design accounts for the male anatomy so that the user can expel urine within the interior of the barrel of said reservoir where none can splash to the exterior. The lower portion of said reservoir 20 narrows, forming a funnel so that the urine will pass freely into said hose 26 which will convey said urine into the bowl of a commode via said dispenser spout 28 .
The sectional view in FIG. 4 illustrates the permanent mounting mechanism of the present invention for said hose 26 to dispense the urine into a commode. Said hose 26 connects to said inlet tube 30 of said dispenser spout 28 . The outer diameter of said hose 26 is slightly smaller then the inner diameter of said inlet tube 30 . Said hose 26 is inserted and held in place within said dispenser inlet tube 30 . The opposite end of said tube widens to create an oval shaped mouth 32 that acts as the spout portion of said dispenser spout 28 . The bottom half of said tube 30 widens dramatically while the upper portion extends outward. The resulting shape has a crooked lower edge that hangs over the edge of the rim of a commode. The seat of said commode rest on top of said dispenser 28 and the weight of said seat holds said spout 28 in place. The wide mouth 32 facilitates smooth flow of urine from the dispenser 28 into the bowl of said commode. The ease and malleability of rubber would make the material an excellent choice for said dispenser spout 28 . Said inlet tube must be made of a material with strong enough rigidity to prevent collapse due to the weight of the seat. A heavy-duty rubber should amply accommodate this need.
While a preferred embodiment of the mountable urine reservoir 10 has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. For example, any suitable flexible material may be used instead of the fabrics that have been described. And although the slicing of food product has been described, there are slight variations, such as shape and size that would make the invention appropriate for other items.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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The mountable urine reservoir is a device designed to address a common problem that exists in commodes installed in mobile vehicles. Because the motion of the vehicle may jostle a person attempting to stand while urinating it is common for urine to splash outside of the commode. This is highly unsanitary. The present invention eliminates this defect in the current systems by providing whereby a person can urinate standing up while inserting their penis within the barrel of a reservoir. Thus the walls of said reservoir would prevent any urine from splashing to the exterior.
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LIST OF PRIOR ART (37 CFR 1.56 (a))
The following reference is cited to show the state of the art:
U.S. Pat. No. 3,886,394
BACKGROUND OF THE INVENTION
The present invention relates to a process for producing pigment-coated phosphors which may be used in the production of a cathode-ray tube of a high contrast for a color television receiver and in which color filter particles (hereinafter referred to simply as "pigment") have been adhered onto the surface of phosphor particles.
More particularly, the invention pertains to a process for producing pigment-coated phosphors wherein onto the surface of a phosphor that radiates wavelengths of light corresponding to a specific portion of visible spectrum by electron-ray stimulation have been adhered pigment particles which function as a color filter that transmits wavelengths of light corresponding to the emission spectrum of the phosphor while absorbing wavelengths of light corresponding to the other portion of visible spectrum.
As a process for producing a pigment-coated phosphor, Mr. S. A. Lipp's process (U.S. Pat. No. 3,886,394) is known. According to the process, pigment-coated phosphors can be produced according to the following procedures:
(1) A pigment is milled in an aqueous solution of polyvinylpyrrolidone (hereinafter referred to simply as "PVP") for several days to 10 days and then diluted with distilled water.
(2) On the one hand, a phosphor is contacted with an aqueous gelatin solution and then washed with water.
(3) To the phosphor coated with gelatin in (2) is added the pigment coated with PVP in (1) so that the pigment may be adhered onto the surface of the phosphor.
The thus produced pigment-coated phosphor has been insufficient in adhesiveness between the pigment and the phosphor, and has a defect in that the pigment and the phosphor are separated from each other when a slurry of the phosphor is prepared, aged and then coated according to a usual method.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved process for producing a pigment-coated phosphor.
Another object of the invention is to provide a process for producing a pigment-coated phosphor having high adhesiveness between the pigment and the phosphor.
The other objects and advantages of the present invention will be apparent from the following description.
These objects can be accomplished by a process for producing a pigment-coated phosphor which comprises the first step of adding a pigment and an anionic polymer emulsion to an aqueous suspension of a phosphor and the second step of carrying out at least one step selected from the group consisting of the step of making the mixture formed in the first step neutral or weakly acidic and the step of adding a cationic polymer emulsion to the said mixture.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Each step of the process of the present invention will be explained below in the order of step.
First of all, a pigment is mixed with pure water and, for example, the mixture is kneaded by a ball mill, etc. for several days.
On the other hand, a phosphor is suspended in water. An anionic polymer emulsion is added to the resulting suspension and the mixture is well mixed.
An appointed amount of the above-mentioned dispersed pigment is added to this system. The mixture is well stirred. The pigment and the phosphor are bonded to each other by one of the following methods:
(1) A method for bonding the pigment and the phosphor with each other by making the system neutral (pH=7) or weakly acidic (pH=about 3 to 7, and preferably 4 to 6) with hydrochloric acid, acetic acid, etc.
(2) A method for bonding the pigment and the phosphor with each other by adding a cationic polymer emulsion to the system.
(3) A method which comprises carrying out both the methods (1) and (2).
In the method (2), it is preferable that the reaction system is almost neutral before the cationic polymer emulsion is added.
Here, as an anionic polymer emulsion, an emulsion of a copolymer of at least one nonionic monomer such as methyl acrylate, ethyl acrylate, butyl acrylate, hydroxypropyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, hydroxypropyl methacrylate or styrene, etc. and one anionic monomer such as acrylic acid, methacrylic acid or itaconic acid, etc. may be used. A copolymer of ethyl acrylate and acrylic acid and a copolymer of ethyl acrylate, methyl methacrylate and acrylic acid are preferable copolymers. In the latter copolymer, the content of methyl methacrylate is preferably less than 50% by weight based on the total weight of monomer units of the copolymer. The anionic polymer emulsion is used in an amount of 0.1 to 2 parts by weight, and preferably 0.2 to 1.0 part by weight, as a solid content per 100 parts by weight of a phosphor. If the amount is less than 0.1 part by weight, the adhesiveness between a pigment and a phosphor is insufficient. If the amount is more than 2 parts by weight, cohesion between phosphors is easy to occur.
Also, as a cationic polymer emulsion, an emulsion of a copolymer of at least one of the above-mentioned nonionic monomers and one cationic monomers such as dimethylaminoethyl acrylate, diethylaminoethyl acrylate, dimethylaminopropyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate or dimethylaminopropyl methacrylate, etc. may be used. The cationic polymer emulsion is used in an amount of 0.05 to 2.0 parts by weight, and preferably 0.1 to 1.0 part by weight, as a solid content per 100 parts by weight of a phosphor.
The process of the present invention is mainly applied to phosphors for color television. However, it goes without saying that the application of the process of the present invention is not necessarily restricted to phosphors for color television but the process is generally applicable to all the phosphors commonly used.
As for the phosphor used in the process of the present invention, for example, manganese-activated zinc orthophosphate phosphor [Zn 3 (PO 4 ) 2 : Mn], manganese-activated magnesium silicate phosphor [MgSiO 3 : Mn], silver-activated zinc cadmium sulfide phosphor [(Zn, Cd) S: Ag], europium-activated yttrium oxysulfide phosphor [Y 2 O 2 S: Eu] europium-activated yttrium oxide phosphor [Y 2 O 3 : Eu], etc. are used as a red luminescent phosphor. Manganese-activated zinc magnesium fluoride phosphor [(ZnFe 2 .MgF 2 ): Mn], manganese-activated potassium magnesium fluoride phosphor [(KF.MgF 2 ): Mn], manganese-activated magnesium fluoride phosphor [MgF 2 : Mn], silver-activated zinc cadmium sulfide phosphor [(Zn, Cd) S: Ag], copper-activated zinc cadmium sulfide phosphor [(Zn, Cd)S: Cu], lead and manganese-activated calcium silicate phosphor [CaSiO 3 : Pb, Mn], etc. are used as an orange or yellow luminescent phosphor. Manganese-activated zinc silicate phosphor [Zn 2 SiO 4 : Mn], copper-activated zinc sulfide phosphor [ZnS: Cu], copper and aluminum-activated zinc sulfide phosphor [ZnS: Cu, Al], copper-activated zinc cadmium sulfide phosphor [(Zn, Cd)S: Cu], zinc-activated zinc oxide phosphor [ZnO: Zn], silver-activated zinc cadmium sulfide phosphor [(Zn, Cd)S: Ag], silver-activated zinc sulfoselenide phosphor [Zn (S, Se): Ag], etc. are used as a green luminescent phosphor. Also, calcium tungstate phosphor (CaWO 4 ), silver-activated zinc sulfide phosphor (ZnS: Ag), silver and aluminum-activated zinc sulfide phosphor (ZnS: Ag, Al), silver and chlorine-activated zinc sulfide phosphor (ZnS: Ag, Cl), cerium-activated calcium magnesium silicate phosphor (2CaO.MgO.2SiO 2 : Ce), terbium-activated yttrium oxysulfide phosphor (Y 2 O 2 S: Tb), titanium-activated calcium magnesium silicate phosphor [(Ca, Mg) SiO 2 : Ti], etc. are used as a blue or violet luminescent phosphor. It is preferable for the phosphors used in the process of the present invention to have an average particle size of 3 to 12μ.
As for the pigments used in the process of the present invention, for example, cadmium sulfoselenide [Cd (S 1-x Se x ), 0<x<1], iron oxide (Fe 2 O 3 ), copper suboxide (Cu 2 O), cadmium mercury red (CdS+HgS), chrome vermilion (PbCrO 4 .PbSO 4 ), silver vermilion (HgS), antimony red (Sb 2 S 3 ), copper ferrocyanide [Cu 2 Fe(CN) 6 ], iodine red [HgI 2 ], zinc iron red [Zn-Fe], the other red ceramic pigments, etc. are used as a red pigment. Basic lead chromate [(PbCrO 4 ) m .(PbO) n ], chrome yellow (PbCrO 4 ), ochre (Fe 2 O 3 .SiO 2 .Al 2 O 3 ), cadmium yellow (CdS), titanium yellow (TiO 2 --NiO--Sb 2 O 3 ), litharge (PbO), minium (Pb 3 O 4 ), zinc iron yellow (Zn-Fe), the other orange or yellow ceramic pigments, etc. are used as an orange or yellow pigment. Chrome green {PbCrO 4 +Fe 4 [Fe (CN) 6 ] 3 .nH 2 O}, cobalt green (CoO.nZnO), chromium oxide (Cr 2 O 3 ) and the other green ceramic pigments, etc. are used as a green pigment. Also, ultramarine blue (3NaAl.SiO 2 .Na 2 S), Berlin blue {Fe 4 [Fe(CN) 6 ] 3 .nH 2 O}, cobalt aluminate (CoO.nAl 2 O 3 ), Cerulean blue (CoO.nSnO 2 ), copper sulfide (CuS) and the other blue ceramic pigments are used as a blue pigment. It is preferable for the pigments used in the process of the present invention to have an average particle size of 0.5μ or less.
A ratio of the amount of a pigment to the amount of the phosphor depends upon the kind of the phosphor, the kind of the pigment, the desired amount of the pigment adhered, etc., but the amount of the pigment used is an amount effective to fulfil a function as a color filter and is usually not more than 15 parts by weight, and is preferably 0.1 to 10 parts by weight, per 100 parts by weight of the phosphor. If the amount of the pigment used is more than 15 parts by weight per 100 parts by weight of the phosphor, the luminous brightness of the resulting pigment-coated phosphor is remarkably reduced.
Examples of a combination of a phosphor and a pigment used in the present invention are shown below.
______________________________________ Red luminescent phosphor: Europium-activated yttrium oxysulfide (Y.sub.2 O.sub.2 S: Eu0 Red pigment: α-Iron oxide Blue luminescent phosphor: Silver-activated zinc sulfide (ZnS: Ag) Blue pigment: Cobalt aluminate Green luminescent phosphor: Copper and aluminum-activated zinc sulfide (ZnS: Cu, Al) Green pigment: Chromium oxide______________________________________
It goes without saying that combinations of a phosphor and a pigment other than the above-mentioned ones can be used in the present invention.
The following examples illustrate the present invention in more detail.
EXAMPLE 1
A mixture of 10 g of cobalt aluminate of an average particle size of 0.3μ as a blue pigment and 90 g of water is milled by a ball mill for 2 days and is then added with 200 g of water to dilute the mixture.
On the other hand, 500 g of a blue luminescent phosphor (ZnS: Ag, Cl) of an average particle size of 10.5μ is dispersed in 500 g of water and is then added with 2.7 g as a solid content of an anionic polymer emulsion comprising a copolymer of ethyl acrylate, methyl methacrylate and acrylic acid. Thereto is added the above-mentioned diluted pigment slurry. The pigment and the phosphor are adhered with each other according to one of the following seven procedures:
(1) The pH of the system is adjusted to 5.9 with dilute hydrochloric acid.
(2) To the system is added 0.25 g as a solid content of a cationic polymer emulsion comprising a copolymer of ethyl acrylate and dimethylaminoethyl methacrylate and the pH of the mixture is then adjusted to 6.8 with dilute hydrochloric acid.
(3) To the system is added 0.5 g as a solid content of the above-mentioned cationic polymer emulsion and the pH of the mixture is then adjusted to 6.3 with dilute hydrochloric acid.
(4) To the system is added 1.0 g as a solid content of the above-mentioned cationic polymer emulsion and the pH of the mixture is then adjusted to 6.4 with dilute hydrochloric acid.
(5) To the system is added 2.5 g as a solid content of the above-mentioned cationic polymer emulsion and the pH of the mixture is then adjusted to 6.5 with dilute hydrochloric acid.
(6) To the system is added 5.0 g as a solid content of the above-mentioned cationic polymer emulsion and the pH of the mixture is then adjusted to 6.7 with dilute hydrochloric acid.
(7) To the system is added 2.5 g as a solid content of the above-mentioned cationic polymer emulsion. The pH of the mixture is 8.3.
Pigment-coated phosphors are obtained through subsequent steps of washing with deionized water, drying and sieving.
The adhesiveness between the pigment and the phosphor is evaluated according to the following method:
10 Grams of a pigment-coated phosphor is entered into 30 ml of an aqueous solution having the following composition:
______________________________________10% Aqueous polyvinyl alcohol solution 100 g5% Neutral aqueous solution ofammonium dichlomate 18 ml10% Aqueous solution of "Tween20"* 1 ml5% Aqueous solution of "PluronicL-92"** 1 mlWater 180 ml______________________________________ *"Tween 20" is a trademark for a polyoxyethylene sorbitan monolaurate manufactured by Atlas Chemical Industries, Inc. **"Pluronic L92" is a trademark for a polyoxyethylene-polyoxypropylene block copolymer manufactured by Asahi Denka Kogyo K.K.
After stirring for 30 minutes, the resulting slurry is allowed to stand for 60 minutes. Thereafter, 5 ml of the supernatant liquid is separated and diluted ten times. The transmission percentage of the diluted solution at 600 nm is measured. The adhesiveness can be evaluated by the transmission percentage value measured. The higher transmission percentage value shows that the adhesiveness between the pigment and the phosphor is larger.
The results obtained are as follows:
______________________________________Procedure Transmission %______________________________________(1) 86.2(2) 87.5(3) 90.5(5) 86.1(5) 90.4(6) 87.0(7) 85.0Known process 41.0(U.S. Patent3,886,394)Blank 92.0(contaning nopigment-coatedphosphor)______________________________________
Thus, it is found that the adhesiveness between the pigment and the phosphor in the pigment-coated phosphors according to the process of the present invention is very large.
EXAMPLE 2
Five pigment-coated phosphors are produced in the same manner as in Example 1 except that the amount of the anionic polymer emulsion added is 0.5 g, 1.0 g, 2 g, 5 g and 10 g, and the amount of the cationic polymer emulsion added is 1 g. The adhesiveness is evaluated for the resulting five pigment-coated phosphors in the same manner as in Example 1. The results obtained are as follows:
______________________________________Amount of anionicemulsion added (g) Transmission %______________________________________0.5 47.51 77.92 86.65 89.710 88.2______________________________________
EXAMPLE 3
Pigment-coated phosphors are produced in the same manner as in Example 1 except that said emulsion of a copolymer of ethyl acrylate, methyl methacrylate and acrylic acid as an anionic polymer emulsion is replaced by an emulsion of a copolymer of ethyl acrylate and acrylic acid (I) or an emulsion of a copolymer of n-butyl methacrylate, isobutyl methacrylate and methacrylic acid (II), said emulsion of a copolymer of ethyl acrylate and dimethylaminoethyl methacrylate copolymer as a cationic polymer emulsion is replaced by an emulsion of a copolymer of ethyl acrylate, methyl methacrylate and diethylaminoethyl methacrylate (III) or an emulsion of a copolymer of n-butyl methacrylate, methyl methacrylate and dimethylaminoethyl methacrylate (IV), the pH of the mixture after addition of the cationic polymer emulsion is adjusted to 6.0 with dilute hydrochloric acid, and the amounts of the anionic polymer emulsion and the cationic polymer emulsion added are 0.5% and 0.2% by weight as a solid content, respectively, based on the weight of the phosphor. The results obtained are as shown in the following table:
Table______________________________________Anionic Cationic Trans-polymer polymer missonemulsion emulsion %______________________________________I III 87.5I IV 90.2II III 88.4II IV 89.1______________________________________
EXAMPLE 4
A mixture of 10 g of cobalt aluminate (CoO.nAl 2 O 3 ) of an average particle size of 0.3μ as a blue pigment and 90 g of water is kneaded by a ball mill for 2 days, and 100 g of water is added to dilute the mixture.
On the one hand, 500 g of silver and chlorine-activated zinc sulfide blue luminescent phosphor (ZnS: Ag, Cl) of an average particle size of 10.1μ is dispersed in 500 g of water. To the dispersion is added 0.65, 0.85 and 1.04% by weight of an emulsion of a copolymer of ethyl acrylate, methyl methacrylate and methacrylic acid as an anionic polymer emulsion based on the weight of the phosphor. The above-mentioned diluted pigment slurry is added to the mixture. Thereafter, 0.15 and 0.20% by weight of the same cationic polymer emulsion as that used in Example 1 based on the weight of the phosphor is added. The pH of the system is adjusted to 4.0 to 6.0 with dilute hydrochloric acid to adhere the pigment and the phosphor with each other.
Through subsequent steps of washing with water, dehydration, drying and sieving according to a usual method, pigment-coated phosphors are obtained. When the adhesiveness of the resulting pigment-coated phosphors is evaluated in the same manner as in Example 1, it is found that the transmission percentage values are 85.0±5%.
EXAMPLE 5
A mixture of 3 g of α-iron oxide (α-Fe 2 O 3 ) of an average particle size of 0.2μ as a red pigment and 50 g of water is kneaded by a ball mill for 2 days, and 100 g of water is then added to dilute the mixture.
On the one hand, 1000 g of europium-activated yttrium oxysulfide phosphor (Y 2 O 2 S: Eu) of an average particle size of 9.5μ as a red luminescent phosphor is dispersed in 1000 g of water. The above-mentioned diluted pigment slurry is added to the dispersion. Thereto is added 3.4 g as a solid content of the same anionic polymer emulsion as that used in Example 1. The pH of the system is adjusted to 6.0. The adhesiveness of the thus obtained pigment-coated phosphor is evaluated in the same manner as in Example 1 except that transmission percentage is measured at a wavelength of 500 nm. As a result, it is found that the transmission percentage value for the product of this example is 81.8% while that for a pigment-coated phosphor obtained according to a prior art process is 48.0%.
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Pigment-coated phosphors which may be used in the production of a cathode-ray tube of a high contrast for a color television receiver can be produced by adding a pigment and an anionic polymer emulsion to an aqueous suspension of a phosphor and then making the system neutral or weakly acidic or adding a cationic polymer emulsion or carrying out both of these steps so that the phosphor and the pigment may be coated with the polymer.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to microelectronic assemblies and, in particular, to substrates used in microelectronic assemblies and methods of fabricating such substrates.
BACKGROUND OF THE INVENTION
[0002] Circuit panels or substrates are widely used in electronic assemblies. Typical circuit panels commonly include a dielectric element in the form of a sheet or plate of dielectric material having numerous conductive traces extending on the sheet or plate. The traces may be provided in one layer or in multiple layers, separated by layers of dielectric material. The circuit panel or substrate may also include conductive elements such as via liners extending through the layers of dielectric material to interconnect traces in different layers. Some circuit panels are used as elements of microelectronic packages. Microelectronic packages generally comprise one or more substrates with one or more microelectronic devices such as one or more semiconductor chips mounted on such substrates. The conductive elements of the substrate may include the conductive traces and terminals for making electrical connection with a larger substrate or circuit panel, thus facilitating electrical connections needed to achieve desired functionality of the devices. The chip is electrically connected to the traces and hence to the terminals, so that the package can be mounted to a larger circuit panel by bonding the terminals to contact pads on the larger circuit panel. For example, some substrates used in microelectronic packaging have terminals in the form of pins extending from the dielectric element.
[0003] Despite considerable efforts devoted in the art heretofore to development of substrates and methods for fabricating such substrates, further improvement would be desirable.
SUMMARY OF THE INVENTION
[0004] One aspect of the present invention provides a method for fabricating a substrate for a microelectronic package. The method desirably comprises forming a molded dielectric layer which surfaces are coplanar with bases and tips of conductive pins of the substrate. Conductive traces may be formed on one or both sides of the dielectric layer.
[0005] Other aspects of the present invention provide substrates such as those fabricated using the disclosed method. Still further aspects of the invention provide microelectronic packages and assemblies which include one or more such substrates.
[0006] The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present invention, which additional aspects will become more readily apparent from the detailed description, particularly when taken together with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a flow diagram illustrating a method in accordance with one embodiment of the present invention;
[0008] FIGS. 2A-2I are schematic, plan ( FIGS. 2A and 2I ), bottom ( FIGS. 2D and 2F ), and cross-sectional views ( FIGS. 2B-2C , 2 E, and 2 G- 2 H) of portions of a substrate during successive stages of the method of FIG. 1 ;
[0009] FIGS. 3A-3B are schematic, cross-sectional views of portions of a substrate fabricated during successive stages of a method according to a further embodiment of the invention;
[0010] FIGS. 4A-4D are schematic, cross-sectional views of portions of a substrate fabricated during successive stages of a method according to another embodiment of the invention;
[0011] FIGS. 5A-5C are schematic, cross-sectional views of portions of a substrate fabricated during successive stages of a method according to yet another embodiment of the invention;
[0012] FIGS. 6A-6D are schematic, cross-sectional views of portions of a substrate fabricated during successive stages of a method according to still another embodiment of the invention;
[0013] FIG. 7A-7B are schematic, cross-sectional views of portions a substrate fabricated during successive stages of a method according to one more embodiment of the invention;
[0014] FIGS. 8A-8D are schematic, cross-sectional views of portions a substrate fabricated during successive stages of a method according to yet further embodiment of the invention; and
[0015] FIGS. 9A-9D are schematic, cross-sectional views of exemplary microelectronic structures using the substrates fabricated in accordance with the method of FIG. 1 .
[0016] Herein, identical reference numerals are used, where possible, to designate identical elements that are common to the figures. The images in the drawings are simplified for illustrative purposes and are not depicted to scale.
[0017] The appended drawings illustrate exemplary embodiments of the invention and, as such, should not be considered as limiting the scope of the invention that may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0018] FIG. 1 depicts a flow diagram illustrating a method 100 for fabricating a substrate having a molded dielectric layer in accordance with one embodiment of the present invention. The method 100 includes processing steps performed during fabrication of the substrate. In some embodiments, these processing steps are performed in the depicted order. In alternate embodiments, at least two of these steps may be performed contemporaneously or in a different order. Sub-steps and auxiliary procedures (e.g., substrate transfers between processing reactors, substrate cleaning sub-steps, process control sub-steps, and the like) are well known in the art and, as such, herein are omitted. Cross-sectional views in the drawings are arbitrarily taken along a centerline 1 - 1 (shown in FIG. 2A only) of a conductive plate of a substrate being fabricated using the method 100 .
[0019] The method 100 starts at step 102 and proceeds to step 104 . A method according to one embodiment of the invention uses a conductive plate 200 having a perimeter 202 ( FIG. 2A ). In this particular embodiment, the plate 200 comprises layers 204 and 206 of electrically conductive principal metal (e.g., copper (Cu)) and a conductive barrier layer 208 , such as a nickel (Ni) layer ( FIG. 2B ). A thickness of the plate 200 is generally selected in range from about 10 to 600 μm (e.g., 50 or 100 μm), whereas the layers 204 , 206 , and 208 typically have thicknesses of about 5 to 300 μm, 5 to 300 μm, and 0.1 to 3 μm, respectively. In one exemplary embodiment, the thicknesses of the layers 204 , 206 , and 208 are 15, 50, and 1 μm, respectively.
[0020] At step 106 , a plurality of conductive pins 210 and at least one optional spacer 212 are formed on the plate 200 ( FIG. 2C ). Each pin 210 comprises a base 210 A and a tip 210 B, and the spacer 212 comprises a base 212 A and a tip 212 B. Widths of the bases 210 A, 212 A and tips 210 B, 212 B are generally selected in a range from about 50 to 1000 μm, for example, 200-300 μm.
[0021] The spacer 212 generally has a closed-loop wall-like form factor and is disposed around an individual section of plate 200 or near the perimeter 202 (as shown), thus surrounding at least some of the pins 210 , as illustratively depicted in a bottom plan view ( FIG. 2D ) taken in the direction of arrow 219 in FIG. 2C . In the particular embodiment, the spacer 212 comprises slots 218 (four slots 218 are arbitrarily shown) which may be used during a molding process of step 108 , as discussed below in reference to FIG. 2E . In one embodiment, the pins 210 and spacer 212 are fabricated from the layer 206 by performing an etch process that uses the barrier layer 208 as an etch stop layer to determine a duration of the etch process.
[0022] The pins 210 are formed at locations facilitating connectivity between elements of an electrical circuit of the substrate being fabricated. Such pins may have different form factors and be organized, for example, in one or more grid-like patterns having a pitch in a range from 100 to 10000 μm (e.g., 400-650 μm).
[0023] In the next stage of the method, at step 108 , a molded dielectric layer 220 is formed on the plate 200 ( FIGS. 2E-2G ). In the molding process, a flowable composition is introduced between the pins 210 and cured to form the dielectric layer. The composition may be essentially any material which will cure to a solid form and form a dielectric.
[0024] For example, compositions which cure by chemical reaction to form a polymeric dielectric, such as epoxies and polyimides may be used. In other cases, the flowable composition may be a thermoplastic at an elevated temperature, which can be cured to a solid condition by cooling. Preferably, the layer 220 , after molding, forms binding interfaces with features of the plate 200 . The composition may further include one or more additives influencing properties of the layer 220 . For example, such additives may include particulate materials such as silica or other inorganic dielectrics, or fibrous reinforcements such as short glass fibers.
[0025] During the molding processes, the plate 200 is sandwiched between a press plate 214 and a counter element 216 (shown using phantom lines) which in this embodiment is part of a molding tool ( FIG. 2E ). The counter element 216 is abutted against the tips 210 B of the pins 210 and the flowable molding composition is injected or otherwise introduced into the space between the plate 200 and counter element 216 .
[0026] In the particular embodiment depicted in FIG. 2E , the molding composition is injected through at least one opening, or gate, 217 in the counter element 216 (as shown) and/or press plate 214 . Slots 218 are used as an escape passage for trapped air, and may also vent excess material of the molding composition. Upon completion of the molding process, the press plate 214 and the counter element 216 are removed ( FIG. 2G ). Ordinarily, the tips 210 B of the pins are free of molding composition at the completion of the molding step. In some instances, a thin film of molding composition may overlie the tips of some or all of the pins. If this occurs, the thin film can be removed by exposing the bottom surface 226 ( FIG. 2G ) of the molded dielectric layer to a brief plasma etching or ashing process which attacks the molded dielectric.
[0027] In a variant of the molding step, the composition may be injected through the slots 218 in the spacer, and openings 217 in the counter element may serve as a vent. Alternatively, one or more openings (not shown) can be formed through layers 204 and 208 of the plate, and these openings may serve either as injection openings for the composition or as vents. In yet another variant, the composition may be provided as a mass disposed on the tips of the pins or on counter element 216 before the counter element is engaged with the tips of the pins, so that the composition is forced into the spaces between the pins as the pins are brought into abutment with the counter element. In another variant, when the plate 200 includes multiple spacers 212 defining individual sections of the plate, the openings 217 may selectively be associated with such sections.
[0028] In another embodiment, the plate 200 may be a portion of a larger frame 242 incorporating a plurality of the plates 200 ( FIG. 2F ). As depicted, the frame 242 illustratively includes sprocket holes 244 and a peripheral wall 246 , which upper surface is coplanar with the tips 210 B and 212 B in the component plates 200 . In this embodiment, the press plate and counter element of the molding tool are extended over the plate 242 and the spacer 246 , respectively. Then, during the molding process, the molding composition is introduced simultaneously into the spaces between the component plates 200 and counter element 216 through individual gates 217 flowably coupled to a runner system of the molding tool. After the press plate and counter element are removed upon completion of the molding process, the component plates 200 may be separated (e.g., cut out) from the frame 242 . Alternatively, such separation may occur after step 110 discussed below in reference to FIGS. 2H-2I .
[0029] The molding step forms the dielectric element, or dielectric layer, with a bottom surface 226 coplanar with the tips 210 B of the pins and coplanar with the tip 212 B of the spacer ( FIG. 2G ). The molding step also forms the dielectric element with a top surface 228 in engagement with the layer 208 and hence coplanar with the bases 210 A of the pins and the base 212 A of the spacer.
[0030] At step 110 , conductive traces 230 are formed from the layers 204 and 206 using, e.g., an etch process ( FIGS. 2H-2I ). Together with the pins 210 , the traces 230 form an electrical circuit of a substrate 240 fabricated using the method 100 . Each trace 230 may be connected to at least one pin 210 and/or to at least one other trace. However, some traces may “float”, i.e., be electrically disconnected from pins and other traces. Likewise, one or more of the pins may remain unconnected to traces, although typically most or all of the pins are connected to traces.
[0031] At least one trace 230 may be a peripheral trace 230 A having a closed-loop pattern and surrounding at least some of pins or other traces as illustratively shown in FIG. 2I , where such traces are depicted using solid lines connected to bases of the respective pins or other traces. In the depicted embodiment, the peripheral trace 230 A is disposed on the spacer 212 . The peripheral trace may further comprise contact areas 232 having greater widths than other portions of the trace. In operation, the peripheral traces, as well as the spacers 212 , may reduce electromagnetic interference (EMI) between electrical circuits present on the same or adjacent substrates.
[0032] The traces 230 may have different widths, including the widths which are smaller than the widths of the bases 210 A and tips 210 B of the pins 210 (as shown in FIGS. 2H-2I ), thus facilitating fabrication of the substrate 240 having high routing density. Generally, the widths of the traces 230 are selected in a range from about 5 to 100 μm (e.g., 20-40 μm), however, portions of traces (e.g., contact areas 234 ) or some traces may have widths greater than 100 μm.
[0033] A substrate 340 A according to a further embodiment has a recess 302 formed in a central region, recess 302 being open to the bottom surface 226 of the dielectric layer. Such a substrate can be formed by a process substantially as discussed above with reference to FIGS. 2A-2I , except that the pin-forming step is conducted so that no pins are formed in the central region, and the molding step is modified by using a counter element (not shown) having a projection extending upwardly in the central region.
[0034] In a substrate 340 B of the embodiment of FIG. 3B , the recess 306 extends all the way to the top surface 228 and thus forms an opening extending through the dielectric layer. Such a recess may be formed by a projection on the counter element which engages the plate during the molding process. In the embodiment of FIG. 3B , the traces do not extend across the recess. However, some or all of the traces may extend across the recess.
[0035] Alternatively, the dielectric layer may be fabricated using a counter element without such a projection, so that the entire bottom surface as molded is flat, and then machined or etched to form the recess 302 or opening 306 . In further variants, two or more recesses may be provided in the dielectric layer. Also, the recess need not be provided in a central region of the substrate.
[0036] A substrate 440 according to a further embodiment of the invention is fabricated using a conductive plate 400 having a single layer 406 of the principal metal (e.g., Cu and the like) ( FIG. 4A ). Conductive pins 410 and an optional spacer 412 are formed on the plate 400 using an etch process or a plating process ( FIG. 4B ). The dielectric layer 220 ( FIG. 4C ) is fabricated using the process described above in reference to FIG. 2E . Then, conductive traces 430 , including optional peripheral traces 430 A, may be formed from the plate 400 using an etch process, thereby completing a process of fabricating the substrate 440 ( FIG. 4D ).
[0037] A substrate according to yet another embodiment of the invention is fabricated using two conductive plates 200 and 500 ( FIG. 5A ). In one embodiment, the plate 500 comprises a single layer 504 of the principal metal. In an alternate embodiment (not shown), a layer of conductive bonding material may be formed on an upper surface 506 of the layer 504 . In one particular embodiment ( FIG. 5B ), the plate 500 is connected to the tips 210 B of the pins 210 using a conventional metal-coupling process, such as thermosonic or ultrasonic bonding, eutectic bonding, solder bonding or the like. Then, during the molding process, the plate 500 serves as a counter element. In the molding operation, the polymer is injected between the plates 200 and 500 . Alternatively, the dielectric layer is molded as described above in reference to FIG. 2E , and then the plate 500 is disposed on a bottom surface of the molded dielectric layer and, using metal-coupling process, is connected to the tips of the pins.
[0038] Then, conductive traces 530 are fabricated from the plate 500 ( FIG. 5C ). The traces 530 may be formed before, after, or contemporaneously with the traces 230 using the same technique (i.e., etch process). The traces 530 may include optional peripheral traces (one peripheral trace 530 A is illustratively shown). Together, the pins 210 and traces 230 , 530 form an electrical circuit of the substrate 540 .
[0039] A process according to a further embodiment uses two conductive plates. Illustratively, such plates are multi-layered plates 200 A and 200 B ( FIG. 6A ), each of which includes principal metal layers 204 and 206 and etch stop layer 208 similar to the layers discussed above with reference to the plate 200 of FIG. 2B . In alternate embodiments, at least one of these plates may be formed from a single layer of the principal metal, such as Cu.
[0040] Pins 210 are fabricated in the plate 200 A as discussed above in reference to FIG. 2C , and, similarly, pins 610 having bases 622 and tips 624 are fabricated in the plate 200 B ( FIG. 6B ). The locations of the pins 610 are selected so that, when the plates 200 A and 200 B are assembled together, the pins 210 and 610 can be mutually interspersed with each other in at least one region of a substrate 640 . For example, pins 210 can be provided as a first regular grid pattern having a particular pitch, whereas pins 610 can be provided as a second regular grid pattern having the same pitch.
[0041] Since the pins are tapered (i.e., tips of the pins are smaller than their bases), in such a substrate the interspersed pins may be disposed closer to one another than the pins formed on the same plate, thus increasing density of the conductive pins in the substrate being fabricated. The tips 210 B of the pins on the first plate 200 A are abutted against the second plate 200 B, whereas the tips 610 B of the pins on the second plate are abutted against the first plate 200 A. Then, using a conventional metal-coupling process, the tips 210 B of the pins 210 are connected to the plate 200 B and the tips 610 B of the pins 610 are connected to the plate 200 A, respectively.
[0042] The dielectric layer 220 is molded in the space between the plates ( FIG. 6C ) using a process discussed above in reference to FIG. 2E where one of the plates may be used as a counter element. Using an etch process, the layers 204 and 208 of the plates 200 A, 200 B are patterned to form the traces 230 and 630 (including optional peripheral traces 230 A and 630 A) of the substrate 640 .
[0043] A process according to another embodiment uses the press plate and counter element forming, around a perimeter of the substrate being fabricated, an enclosure for the molding composition. The substrates may be fabricated with a peripheral spacer (substrate 740 A in FIG. 7A and substrates in FIGS. 9C-9D ), as well as without the spacer (substrate 740 B in FIG. 7B ).
[0044] A process according to yet further embodiment uses a single plate 804 ( FIG. 8A ). The plate 804 is formed from the principal metal (e.g., copper plate) to a thickness from about 10 to 300 μm. Then, a barrier layer 808 (e.g., Ni barrier layer) is deposited on a bottom surface of the plate 804 ( FIG. 8B ). The barrier layer 808 is patterned to form, at pre-determined locations, pads 805 for conductive pins and optional spacers ( FIG. 8C ). Conductive pins 810 and spacers 812 may be formed on the pads 805 using, for example, a plating process ( FIG. 8D ). In the depicted embodiment, a resulting structure includes a peripheral spacer having slots 818 . Such a structure may further undergo molding and etching processes discussed above in reference to FIGS. 2D-2I . Structures with plates and pins can be formed in other ways as well. For example, such a structure can be formed by coining a single metal layer or a multi-layer metallic laminate.
[0045] Substrates fabricated according to yet further embodiments the method of FIG. 1 may comprise combinations of features discussed above in reference to the substrates 240 , 340 A- 340 B, 440 , 540 , 640 , and 740 A- 740 B. For example, the substrates 440 , 540 , 640 , and 740 A- 740 B may include recesses and/or openings, like those included in substrates 340 A- 340 B.
[0046] FIGS. 9A-9D depict a series of schematic, cross-sectional views of exemplary structures using the substrates fabricated in accordance with the method of FIG. 1 .
[0047] Microelectronic elements, or devices, may be mounted on the substrates using techniques such as a ball-bonding and/or wire-bonding technique. In FIGS. 9A-9D , the devices adapted for mounting using the ball-bonding and wire-bonding techniques are collectively denoted using reference numerals 906 and 908 , respectively. Similarly, such techniques may be used for connecting the substrates stacked on one another or juxtaposed substrates.
[0048] More specifically, the FIGS. 9A , 9 B, and 9 C depict exemplary microelectronic structures or units 901 , 902 , and 903 each comprising one substrate 240 , 540 , and 640 , respectively. In the embodiment depicted in FIG. 9A , the substrate 240 is disposed on and connected to a circuit panel 912 and includes an electrically conductive EMI shield 910 . The tip ends of the pins of substrate 212 are solder bonded to contact pads of circuit panel 912 . The microelectronic devices 906 , 908 and the EMI shield 910 are mounted on an upper surface 241 of the substrate 240 . The EMI shield 910 is ball-bonded to the peripheral trace 230 A of the substrate and, as such, electrically connected to the spacer 212 . Herein, the spacer 212 is further connected to ground contact pads 914 of the circuit panel 912 . For example, the unit including substrate 240 , devices 906 and 908 and shield 910 may be mounted to panel 912 using solder-bonding techniques commonly used for surface-mounting microelectronic elements on circuit boards. In embodiments shown in FIG. 9B and 9C , the devices 906 and 908 are mounted on both sides of the substrates 540 and 640 , respectively.
[0049] The substrates discussed above may be interconnected to form multi-substrate structures. FIG. 9D depicts an exemplary assembly, or package, 904 comprising two stacked units 640 A and 640 B, each of which includes a substrate as discussed above. One of the stacked units (denoted using a reference numeral 640 B) has a recess formed in the molded dielectric layer of the substrate. Thus substrate of the other unit 640 A constitutes a panel having a top surface, contact pads exposed at the top surface of said panel, and an additional circuit element 906 mounted to said panel and extending upwardly therefrom. The dielectric layer of unit 640 B overlies the top surface of the panel in unit 640 A. The additional circuit element 906 is received in the recess. The tip ends of the pins in unit 640 A are bonded to the contact pads of said panel. Illustratively, the peripheral lines and a portion of the traces of the stacked substrates of the units 640 A and 640 B are also connected using such a technique to form the assembly 904 . In a variant, the assembly 904 may comprise more than two substrates, or the substrates of different types.
[0050] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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Substrates having molded dielectric layers and methods of fabricating such substrates are disclosed. The substrates may advantageously be used in microelectronic assemblies having high routing density.
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FIELD OF THE INVENTION
The present invention relates to devices that manage, control, or suppress sparks, and more particularly, to a method and apparatus for suppressing sparks that are produced in industrial processes and become conveyed in air handling systems and dust collection systems.
BACKGROUND OF THE INVENTION
There are many industrial processes that result in the production of sparks, either actively, passively or accidentally. Active production of sparks include those processes that generate a tremendous quantity of sparks, for example, welding and plasma cutting operations. Passive production of sparks refers to processes that are known to periodically generate sparks, yet spark production is relatively infrequent, for example a drying process that produces sparks primarily during startup and shutdown periods of operation. Accidental spark production refers to spark generation as the result of an accidental occurrence, for example, sparks are generated by the impact between two objects in an industrial process, and then the sparks become entrained in a process airstream. In many of these processes, the sparks are conveyed in a dust collection or air handling filtration system that treats the air surrounding the industrial process. The sparks are relatively small embers of burning substances discharged from a body in combustion. These sparks can cause damage to dust collection and filtration systems. For example, in a dust collection system, nuisance sparks carried downstream in a duct can burn through-holes in the filtration system's filter media, resulting in hazardous fires, or at a minimum, degradation in the filtration system's ability to effectively treat the air stream. Relatively large sparks are capable of also igniting combustible dust that may collect on the filter media, potentially causing catastrophic fires. Even without such fires, smaller sparks may burn-damage the filter media, requiring frequent replacement of the filter media, thereby significantly adding to the cost of operating and maintaining the filtration system.
Conventional spark detection and extinguishment systems for reducing the threat and incidence of fire are typically complex and may involve the application of a chemical retardant and/or water to the affected area upon detection of a spark(s). These conventional suppression systems are expensive, vulnerable to drift, tampering and malfunction. Additionally, activation of these systems often results in compromising the filtration system, because the system may need to be cleaned to remove the extinguishing substances and/or the byproducts of mixing and reacting of extinguishing substances with particulates in the process stream. Conventional extinguishment systems often use water deluge; these systems may be incompatible and potentially hazardous with particulate loading (i.e., some metal dusts) in certain industrial air streams. Also, filter media wetted in deluge systems may need to be removed and replaced with dry filter media, incurring significant maintenance costs and operational downtime.
Particularly for those industrial processes that take place on a smaller scale, incorporating known spark suppression systems is prohibitively expensive; therefore, there are few economically viable options available for smaller scale operations to have effective spark suppression capability.
Therefore, there is a need to provide a simple, economical and effective spark suppression system that may be easily and affordably installed in both large and small-scale industrial processes.
SUMMARY OF THE INVENTION
In accordance with the present invention, a spark suppression device is provided that effectively extinguishes sparks, yet is easily installed in any duct of an industrial process, such as air handling or dust collection systems, hereinafter collectively referred to as air handling systems. The term “suppress” as used herein shall mean the general management or control of sparks to include, but not limited to, the ability to extinguish and arrest sparks in an industrial process. According to a preferred embodiment, the spark suppression device is in the form of a static mixer or tubulator device that is mounted within the duct of the air handling system upstream of the filter media. The static turbulator includes a plurality of vanes or blades that extend substantially transverse to a general direction of air flow through the duct. The device extinguishes sparks by taking advantage of various thermo-fluid principles discussed further below, as well as by physical impact of the sparks against the blades of the device.
Most sparks created in the industrial processes are small and burn out almost immediately on their own, thus not causing any damage to the air handling system. Nevertheless, some sparks are indeed large enough and hot enough to be conveyed through ductwork for relatively long distances. These sparks are typically between 100-200 microns in size. Because spark embers are buoyant due to a bubble or casing of hot air that surrounds each spark, sparks in this size range may travel relatively long distances in ductwork. Thus, sparks may move at velocities that substantially match the air stream, until the spark is arrested against the filter media. Upon contacting the filter media, the hot air bubbles get stripped from the spark embers, leaving the burning embers in contact with the combustible filter media. If a spark is large enough and hot enough, the filter media will ignite, and so too will combustible dust caked on the filter media. Sparks generated from many well-known industrial processes may have temperatures between 700-1400 deg. F. It is also known that a spark measuring approximately 150 microns in diameter and over 700 deg. F can provide enough heat to start a fire or burn a sizeable through-hole in filter media. The actual spark ember may have a temperature between 1200-1400 deg. F, and the bubble or casing around the ember may be between 700-800 deg. F.
The spark suppressor of the present invention takes advantage of various thermo-fluid principles to extinguish sparks. One attribute of the present invention that helps to extinguish sparks is disruption of the spark ember/hot air bubble equilibrium. A spark passing through the spark suppressor is subjected to a sudden increased pressure that disrupts the hot air bubble surrounding the spark ember. This pressure increase is due to a decreased air velocity of the airstream as it passes across an enlarged entrance section of the spark suppressor. This enlarged entrance section can also be described as providing a sudden entrance expansion, thereby creating the pressure increase. Accordingly, the ember/hot air bubble equilibrium is disrupted under the influence of increased pressure and becomes unstable, and the spark ember begins to separate from the hot air bubble. The cooler air that subsequently surrounds the spark ember more rapidly transfers heat away from the ember and thereby helps to extinguish the spark.
Another attribute provided by the present invention can be referred to as a “sling-shot” effect or momentum conservation that also helps to separate the spark ember from the hot air bubble. Due to expansion as mentioned above, the airstream velocity on the upstream side of the turbulator decreases rapidly in approaching blades of the turbulator. However, because a spark ember is of much greater density than the surrounding airstream, the ember, in maintaining momentum, separates from the surrounding hot air bubble. Thus, the spark ember is slung forward and away from the slower moving hot air bubble. Therefore, in addition to the increased pressure that helps to strip away the hot air bubble from the spark, the momentum of the spark ember itself also helps to separate the hot air bubble from the spark ember.
Another attribute of the present invention that helps extinguish sparks is the turbulence created by the blade arrangement as the sparks travel downstream beyond the device. The swirling and counter-swirling blade arrangement greatly increases turbulence downstream of the spark suppressor that contributes in extinguishing spark embers, because a source of cooler air continually swirls around the ember, rapidly transferring heat away by convection. Turbulent air enveloping the sparks is of sufficient magnitude that extinguishes sparks in a manner similar to a person blowing out the already dying flame of a candle.
Yet another attribute of the present invention that helps extinguish sparks is the physical contact/impact of the spark embers against the blades of the device. The blades are preferably arranged such that the leading edge of each blade overlaps the trailing edge of one adjacent blade when viewing the device along a longitudinal path through the duct passageway. Thus, open gaps between the blades as viewed in the longitudinal direction are effectively eliminated. Accordingly, the great majority of spark embers will physically impact the blades. Depending on the speed of the spark embers, contact of the embers against the blades can cause the embers to break up and disintegrate into smaller-sized embers, which overall provides larger surface area for convecting heat, thereby cooling the spark faster. Also, contact of the spark embers against the blades rapidly slows their speed and causes them to drop out of the airstream sooner than if they were still moving unimpeded with the airstream. Thus, if the spark suppression device is placed far enough upstream of an air filtration unit, many sparks will not travel the distance required to contact the filter elements.
Yet another attribute of the present invention that helps to extinguish sparks is the redirecting effect of the blades' curvature wherein spark embers conveyed across the static mixing portion of the spark suppressor are redirected from largely a longitudinal path of travel to a path of travel that has a radial component. With a radial component in the path of travel, the spark embers impact the inside walls of a downstream converging section of the spark suppressor and/or the inside walls of the downstream duct that adjoins the converging section.
There are a number of factors that affect the performance of the spark suppressor device. One factor is the particular arrangement, size, and curvature of the blades. Smaller blades with less curvature create less pressure drop across the device as compared to larger blades with greater curvature. Spark embers extinguish quickly upon impacting a surface; a spark suppressor with overlapping blades virtually eliminates the chance that a spark may pass through without impacting blade surfaces. Typically, the greater the blade overlap, the larger the blade required, which results in higher pressure drop for the same airstream flowrate.
Another factor affecting performance is airstream velocity. At less than approximately 400 fpm airstream velocity in the duct (duct velocity), the turbulator is appreciably less effective in creating sufficient turbulence downstream to suppress sparks. At duct velocities in excess of 7,500 fpm, the blades are less effective in creating sufficient turbulence downstream to suppress sparks; at duct velocities greater than 7,500 fpm, gaps between the blades behave more as orifices, which reduces the influence of blade curvature. Also, at high velocities, the pressure drop across the spark suppressor is exceedingly high. The spark suppressor of the present design should ideally be operated at duct velocities between 1000 to 6000 fpm to achieve maximum spark suppression. Most industrial processes are designed and operated at duct velocities between 1000 to 6000 fpm. Therefore, with respect to duct velocity, pressure drop and spark suppression, the present invention is ideal.
The spark suppressor of the present invention is successful in suppressing sparks by rapidly lowering the temperatures of the sparks to within 50 deg. F. of the surrounding airstream, and wherein the spark suppressor operates at pressure drops of 1 inch water gage or less for duct velocities less than 4000 fpm. The present invention offers a lower pressure drop alternative over conventional spark drop-out boxes. The present invention operates under a lower pressure drop and therefore lowers power requirements, thus energy costs are significantly reduced.
In addition to suppressing sparks, the static mixing portion of the spark suppressor also destratifies temperature and concentration gradients; therefore, in applications where relatively high temperatures may threaten to cause duct fires, the device rapidly drives localized extreme high temperature in the flow stream toward the average temperature and thereby decreases the threat of fire. In applications where the concentration of particulate and other constituents elevate locally to lower explosive limits, there is threat of fire. The static mixing portion of the device decreases this threat of fire by homogenizing particulate concentration, which prevents concentrations from reaching lower explosive limits.
The monolithic design of the present invention has no moving parts that could potentially malfunction, which is most favorable for seeking absolute fire and burn-damage prevention. Being integral to the duct work, the spark suppressor does not rely on any auxiliary power or controls, rather, it is always working whenever the fan of the air handling system is running, which results in 100% spark detection and 100% response to sparks.
Other features and advantages of the present invention will become apparent from review of the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an air handling system incorporating a spark suppression device of the present invention;
FIGS. 2A and 2B illustrate an example of a prior art spark suppressing device;
FIG. 3 is a perspective view of a first preferred embodiment of the spark suppression device of the present invention installed within a length of duct;
FIG. 4 is a perspective view of a second preferred embodiment of the spark suppression device of the present invention;
FIG. 5 is a perspective view of an air booster assembly that can be used in conjunction with the spark suppression device in order to help clean the blades of the device;
FIG. 6 is a perspective view of the air booster assembly installed upstream of the spark suppression device; and
FIG. 7 is a front or upstream elevation view of the spark suppression device of the present invention further illustrating the arrangement of the blades and particularly the overlap of the blades to eliminate open gaps as viewed longitudinally through the device.
DETAILED DESCRIPTION
Referring to FIG. 1 , the spark suppressor 10 of the present invention is illustrated as being installed within an air handling system. A typical air handling system includes the machine/process 16 which generates sparks, either actively, passively or accidentally, and a filtration inlet line/duct 18 which conveys contaminated air and sparks to a filtration unit 12 . The filtration unit 12 includes a filter housing 22 , and one or more filter elements 24 . In this particular system, the filter elements 24 are shown as cartridge-type filters, which are replaced periodically over time as they become clogged/caked over with particulate. A filtration outlet line/duct 20 allows conveyance of filtered air back into the environment through discharge exit duct 21 . A fan 14 draws the airstream through the filtration unit. The fan 14 is representative of any standard process fan providing enough power to draw air-flow through the system and to thereby draw particulate away from the machine/process 16 , so that particulate carried in the airstream can be treated within the filter unit 12 .
FIGS. 2A and 2B are representative of the closest known prior art. This prior art consists of an air mixing apparatus 30 typically used in heating, ventilating and air conditioning (HVAC) systems for statically intermixing stratified airstreams, thereby improving the heating/cooling efficiency of the HVAC system. One such prior art air mixing apparatus has been installed at an industrial location for spark suppression on an industrial process. The structure of this static air mixing apparatus is defined by an outer sleeve or wrap 32 that houses a plurality of outer vanes 38 . An inner sleeve or wrap 34 houses an inner set of vanes 36 . A support panel 40 is sized to match the shape of the particular duct in which the static air mixing device is installed.
Although the prior art illustrates a static air mixing device that has been used for spark suppression, the particular design considerations for a static air mixing device versus that of the spark suppression device of the present invention are significantly different. For example, with respect to the prior art shown in FIG. 2B , the outer set of vanes 38 have substantial gaps 42 between some blades when viewed longitudinally. Similarly, there are relatively large gaps 44 that exist between the inner set of blades 36 when viewed longitudinally. Because of these large gaps, a significant number of sparks may pass unimpeded through the prior art spark suppression device, and consequently, the sparks are conveyed down the duct where they may potentially cause ignition and combustion. Whereas, in the present invention with overlapping blades, sparks inevitably impact the blades. Additionally, because of the overall geometry and gaps between the blades, the pressure drop across the prior art static air mixing device is less than that of the present invention. Accordingly, any inherent spark suppression benefits achieved by the prior art device due to spark equilibrium disruption or momentum conservation are significantly less in comparison to the present invention. Thus, the only attribute of the prior art device that absolutely contributes to spark suppression is the downstream turbulence of the airstream created by the blades of the prior art device. Therefore the present invention is superior over the prior art in suppressing sparks, thereby reducing the risk of sparks threatening life and damaging property.
Referring to FIG. 3 , the spark suppression device 10 of the present invention is characterized by a static mixer portion including set of inner vanes/blades 62 , a set of outer vanes/blades 64 , and an intermediate sleeve or wrap 60 interconnecting the distal ends of the inner set of blades to the proximal ends of the outer set of blades. The distal ends of the outer set of blades abut the interior surface of the outer sleeve or wrap. The inner set of blades 62 converge at their proximal ends and are joined by a central hub 66 . The inner set of blades 62 have a curvature in the downstream direction as shown, and the outer set of blades 64 have different curvature to the inner set of blades 62 , yet also a curvature in the downstream direction. The embodiment of FIG. 3 provides inter-mixing of an airstream passing through the duct to effect destratification of the airstream.
Referring again to FIG. 3 , the static mixing portion of the spark suppression device 10 is preferably mounted between upstream and downstream transition sections 52 . The transition sections 52 may also be referred to as spark cones, or simply as sections of duct that increase in diameter as they approach the static mixer portion. As shown in FIG. 1 , the cones 52 are mounted in line with the filtration inlet duct 18 . The device 10 preferably includes a pair of these spark cones 52 . An outer sleeve or wrap 54 interconnects the adjacent ends of the transition members 52 . The smaller-diameter openings at opposite ends of spark cones may include a flange 56 enabling the transition members to mount in line with an existing duct. In lieu of flanges 56 , the transition members may include other means of connection so that the transition members may mount in line with the adjacent upstream and downstream sections of duct.
FIG. 4 illustrates another preferred embodiment of the present invention. In this preferred embodiment, there is a single set of blades 68 that extend from the central hub 66 to the inner surface of the outer wrap 54 . This simplified version of the spark suppression device of the present invention provides adequate intermixing of the airstream and at least equal capability with respect to spark suppression by disruption of spark equilibrium by momentum conservation. The hub 66 in FIG. 4 is also larger than the hub 66 in FIG. 3 . As discussed further below, some additional spark suppression benefits may be achieved with a larger hub.
Referring back to FIG. 3 , the hub 66 may be modified to include a blocking or center plate 67 , shown in dashed lines, that is attached over the leading edge of the hub 66 . The center plate 67 prevents sparks from passing unimpeded through an otherwise more open center area. Use of a center plate also causes sparks traveling generally along the longitudinal center axis of the airstream to be deflected radially outward, thus causing the sparks to make contact with the more radially outward lying portions of the inner blades. This radial deflection of a spark, being transverse to the longitudinal centerline of the duct, is a result of vortex shedding of the airstream created by the blocking effect of the center plate. The enlarged hub 66 of FIG. 4 can also achieve some of the same benefits of the blocking plate 67 since some of the center open area is covered by the enlarged hub.
FIG. 5 illustrates an air booster assembly 70 that can be used to apply a pulse of compressed air across the spark suppression device, thereby helping to clean particulate and debris that may adhere to the blades. Therefore, there may be a need to periodically remove the adhered material from the blades by providing a pulse of air (by automatic or manual means) that effectively dislodges the particulate and debris from the blades. The air booster assembly 70 includes a pulse valve 72 and a supply of compressed air/fluid connected to the valve that is delivered via pipe 74 . A pulse distribution pipe 76 is mounted transversely within a section of duct 86 just upstream of the spark suppression device 10 . The pulse distribution pipe includes one or more orifices 78 that release a pressure wave through the duct and against the spark suppression device 10 . A control line 80 (either electric or pneumatic) is used to selectively control the operation of valve 72 for delivering a desired frequency and duration of pulse air. Conveniently, a pulse orifice alignment indicator 82 may be mounted to the pulse distribution pipe 76 enabling a user to confirm the direction that the orifices 78 face. Preferably, the pulse distribution pipe extends through the center of the duct section 86 . Openings may be formed through the duct walls allowing the ends of the pipe 76 to pass therethrough. A sealing gasket 84 may be used to seal the openings in the duct with respect to the installed distribution pipe 76 . The control line 80 may communicate with either an industrial controller (not shown) for automatic pulse control, or to a manual switch (not shown), which would allow an operator to selectively control passage of compressed air/fluid through the valve 72 .
Referring to FIG. 6 , an elevation view taken along a longitudinal centerline of the preferred embodiment of FIG. 3 is illustrated. The leading or upstream edges 88 of the inner set of blades 62 are illustrated as continuous lines, while the trailing or downstream edges 90 of the blades 62 are illustrated as dashed lines. As shown, when viewed along the longitudinal centerline, for each inner blade, there is a definable overlap between the leading edge 88 of each inner blade and the trailing edge 90 of one adjacent inner blade. As the inner blades extend radially outward, the overlap may decrease; however, there is preferably no clear open gap between adjacent blades, which prevents sparks having a linear path of travel to pass unimpeded therethrough. Although it is theoretically possible for a spark to pass through the spark suppression device without actually contacting a blade, such clear passage could only occur if the spark rapidly changed direction as it passed through the device, which is a highly unlikely event at any flowrate. As previously mentioned, because a spark ember has a density greater than the surrounding airstream, the spark ember tends to maintain its linear direction of travel through the duct; therefore, the overlapping blade arrangement of the preferred embodiment causes virtually all sparks to make contact with the blades.
Also shown in FIG. 6 is the particular arrangement of the outer set of blades 64 . The leading or upstream edges 92 of the outer set of blades 64 are illustrated as continuous lines, while the trailing or downstream edges 94 of the blades 64 are illustrated as dashed lines. A definable overlap also exists with respect to the leading edge of each outer blade and the trailing edge of one adjacent outer blade. Again, this overlap virtually eliminates the likelihood that a spark may simply pass through the outer set of blades without contacting the blades. In general, an increase in the depth of the blades, as measured by “D” in FIGS. 3 and 4 , requires less curvature to achieve the same overlap between adjacent blades in preventing unobstructed passage of sparks.
By the foregoing described invention, it is shown that a static spark suppression device is provided that effectively suppresses sparks to prevent fire and burn damage to air handling and dust collection systems. While the invention has been described with respect to preferred embodiments, it shall be understood that various changes and modifications may be effected that fall within the scope of the claims appended hereto.
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A spark suppression device includes a plurality of blades or vanes that are mounted transversely in a duct of an air handling/dust collection system communicating with a spark source. A controlled flow of air carries sparks from the spark source through the spark suppression device. Sparks are suppressed by turbulence created in the airstream from the blades that have a downstream curvature. The turbulence strips away a hot air bubble surrounding a spark ember, thereby effectively cooling the spark and significantly reducing combustion at the spark ember. Other attributes of the invention contributing to spark suppression include an overlapping arrangement of the blades that results in high-velocity impact of the sparks against the blades, thereby breaking up the spark embers into smaller embers, and creation of rapid increased pressure within the spark suppression device that also helps to strip away the spark ember from the surrounding hot air bubble.
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TECHNICAL FIELD
[0001] This invention relates to processes and structures for improving heat dissipation from electronic devices, and more particularly to thermal interfaces between integrated circuit devices and heat sinks.
BACKGROUND OF THE INVENTION
[0002] Conventional techniques for conducting heat from an integrated circuit device to a heat sink, such as an aluminum body, have generally included the use of solder joints or thermal grease to achieve the desired thermally conductive interface between the integrated circuit device and the heat sink. However, while solder joints provide good thermal conductivity, the relatively large difference between the coefficient of thermal expansion of the integrated circuit device substrate (typically silicon) and the heat sink induces fairly large stresses on the solder joints during thermal cycling of the device, leading to cracking and fracture, resulting in an undesirably short service life. While conventional thermal greases eliminate or reduce the problems associated with the mismatch between the coefficient of thermal expansion of the integrated circuit device substrate and the heat sink, thermal greases offer very limited thermal performance (i.e., they do not facilitate thermal conductivity comparable to solder joints).
SUMMARY OF THE INVENTION
[0003] The invention involves the use of a thermal interface composite material disposed between an integrated circuit device and a heat sink, wherein the thermal interface composite material comprises a metal screen defining openings and a bonding agent incorporated into the openings of the metal screen. The thermal interface composite material provides a superior combination of bonding strength and thermal conductivity that is not achieved with conventional thermal interface materials.
[0004] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0006] FIG. 1 is a top plan view of a compressed copper mesh useful as the metal screen in the thermal interface composite material of the invention.
[0007] FIG. 2 is a cross-sectional view of an electronic component having a thermal interface composite material disposed between an integrated circuit device and a heat sink to form an electronic component in accordance with the invention.
[0008] FIGS. 3A-3F illustrate an assembly process in accordance with the invention.
[0009] FIGS. 4A-4E illustrate an alternative assembly process also in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] In accordance with the various aspects and embodiments of this invention, a thermal interface composite material comprised of a metal screen defining openings and a bonding agent incorporated into the openings is disposed between an integrated circuit device and a heat sink to provide an exceptional combination of bonding strength and thermal conductivity.
[0011] FIG. 1 shows a metal screen 10 comprised of copper filaments or threads 15 that are woven into a fabric mesh defining openings 20 . The illustrated metal screen 10 has flattened upper surfaces 25 and similar flattened surfaces on the opposite side (not shown). This flattening of the opposite surfaces of the metal screen that contact the heat sink and the circuit board substrate can be achieved by compressing a conventional wire screen between two planar surfaces or platens. A desirable flattening can be achieved with a standard 100 mesh screen or sieve comprised of woven copper filaments or threads having a diameter of 0.0045 inches using a force of from about 200 psi to about 800 psi. While flattening of the upper and lower surfaces of the screen is not essential, it increases the area of contact between the metal screen and the integrated circuit device and between the metal screen and a heat sink when it is incorporated into a composite thermal interface disposed between the integrated circuit device and the heat sink.
[0012] While the metal screen is most desirably provided in the form of a wire mesh screen having woven metal filaments or threads, other metal screens may be used. Examples of other suitable metal screens for use in the composite interface materials of this invention include metal screens prepared by perforating a metal foil, such as by etching, punching, or otherwise providing a plurality of openings.
[0013] Copper and copper alloys are currently a preferred material for use in making or providing the metal screens used in the composite thermal interfaces of this invention because of their high thermal conductivity, low cost and malleability. However, other metals may be employed, such as nickel, silver, gold, aluminum, iron and alloys thereof. Metal screens comprised of woven metal filaments or threads which may be used include those in which the filaments have a diameter of from about 1 mil (26 micrometers) to about 50 mils (1300 micrometers) and define openings of from about 1 mil (26 micrometers) to about 50 mils (1300 micrometers).
[0014] The structural bonding agent that is incorporated into the openings defined in the metal screen may be either a thermosetting resin material or a thermoplastic material. Suitable thermosetting materials that may be used for preparing the thermal interface composite materials of this invention include epoxy reins, phenolic resins, melamine-formaldehyde resins, etc. with epoxy resins being preferred. The thermosetting resin being used to prepare the composite thermal interfaces of the invention may be so-called “B-stage” resins, which refers to a stage of some thermosetting resins characterized by softening up of the resin when heated and swelling when in the presence of certain liquids. So-called “snap-cure” epoxy resins such as those disclosed in U.S. Pat. No. 5,770,706 may be utilized. Examples of thermoplastic materials that may be employed in the composite thermal interfaces of this invention include polyvinyl acetate, acrylic solvent cement (e.g., polymethylmethacrylate dissolved in methyl chloride), acrylic, toughened acrylic resins, cyanoacrylates, silicone resins, polyamines and anaerobic acrylic acid diesters.
[0015] In general, the electronic components having a composite thermal interface material disposed between an integrated circuit device and a heat sink is prepared by disposing between the integrated circuit device and heat sink, a thermal interface composite material comprising a metal screen defining openings and a fluid structural bonding agent incorporated in the openings, and subsequently hardening or curing the fluid structural bonding agent. In the case of thermosetting compositions, the expression “hardening” or “curing” refers to a chemical cross-linking reaction that causes the liquid resin composition to become irreversibly converted into a solid material, which typically cannot be reconstituted in any way except by decomposition. In the case of thermoplastic materials, hardening or curing refers to either evaporation of a solvent or solidification of a molten thermoplastic material.
[0016] A preferred technique for preparing an electronic component in accordance with the invention is illustrated in FIGS. 3A through 3F .
[0017] In FIG. 3A , a metal screen 10 is placed on heat sink 30 . In the illustrated embodiment, heat sink 30 has a plate-like structure or shape. However, it should be understood that the heat sink may have other shapes, and may include fins or other structures to enhance transfer of heat from heat sink 30 to the surrounding air by convection.
[0018] Thereafter, as shown in FIG. 3B , a structural adhesive agent composition 40 is applied over metal screen 10 and spread as shown in FIG. 3C so that composition 40 enters into openings in metal screen 10 , and preferably fills the openings. As shown in FIG. 3D , the integrated circuit device is placed over screen 10 impregnated with adhesive composition 40 . Pressure in then applied as suggested in FIG. 3E , such as with a clamp, and the adhesive composition 40 impregnated into the metal screen 10 is hardened or cured. The pressure in then removed and the completed device is shown in FIG. 3F .
[0019] In an alternative assembly process, also in accordance with the invention, a screen 10 is placed on heat sink 30 as shown in FIG. 4A , and an adhesive is applied by means of a roller 50 as shown in FIG. 4B . The steps illustrated in FIGS. 4C through 4E are analogous or the same as those illustrated in FIGS. 3D through 3F and described above.
[0020] Examples of bonding agents which may be employed in accordance with the invention are listed in Table 1.
[0000]
TABLE 1
Other Potential Bonding Agents
Material
CTE
Cure Cycle
Cookson 3090
38
150° C. 20 minutes
ShinEtsu 9030
200
150° C. 20 minutes
Loctite 3509
72
During solder reflow
No-Flow Material
82
During solder reflow
Henkel OM 360
280
200° C. melt
Loctite 214-HP
80
150° C. 20 minutes
B-stage epoxy
74
Varies
[0021] The relevant material properties characterizing the strength of the adhesive bond in terms of shear force and the thermal conductivity for various known thermal interface materials (Examples 1-5) is compared with a composite thermal interface material in accordance with the invention (Example 6) comprising a copper mesh screen impregnated with an epoxy resin (Loctite 214-HP). The results are listed in Table 2 below. The composite thermal interface material of the invention exhibits outstanding thermal conductivity as compared with known thermal interface materials, and a bonding strength comparable to pure epoxy resin, which is an extremely poor thermal conductor.
[0000]
TABLE 2
Relevant Material Properties
Shear Force
Example
Material
(0 Hrs)
Thermal Conductivity
1
Bergquist Dove
<5 kg
15
W/m ° K
2
AATA Film
<5 kg
83
W/m ° K
3
Sn 75-Pb
34 kg
45
W/m ° K
Solder
4
Indium Solder
22 kg
86
W/m ° K
5
Epoxy
86 kg
.7
W/m ° K
6
Cu Mesh
72 Kg
108
W/m ° K (measured
214-HP)
[0022] It will be understood by those who practice the invention and those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law.
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An improved thermal interface material for conducting heat away from an integrated circuit device into a heat sink is a composite material including a metal screen defining openings and a hardened structural bonding agent incorporated into the openings of the metal screen. The improved composite thermal interface material achieves outstanding bonding properties superior to conventional thermal interface materials, while also exhibiting exceptional thermal conductivity.
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CROSS REFERENCE TO RELATED APPLICATIONS
This Non-Provisional Application claims benefit to U.S. Provisional Application Ser. No. 60/748,057 filed Dec. 7, 2005.
FIELD OF THE INVENTION
The field of the invention generally relates to fasteners, and more particularly, to fasteners adapted for use in automobile air bag attachment systems.
BACKGROUND OF THE INVENTION
It is known that air bags are used in vehicles to provide passenger safety in the event of an accident. It is further known that air bag attachment systems are used to secure the air bag to the vehicle structure. Typically, the known air bag attachment systems include fasteners that utilize metal inserts to provide the requisite high retention of the air bag to the vehicle structure. Some of the known designs incorporate a metal insert and utilize screws to attach the fastener to the vehicle structure. Drawbacks and disadvantages with such fasteners exist. For example, the employment of metal inserts and screws increase the tendency of the fastener components to buzz, squeak, and rattle while the vehicle is in use. Also, the design of the metal inserts may not be conducive to a visual inspection of the air bag fastener to ensure the complete and correct installation of the fastener.
The present invention addresses these and other drawbacks with known fasteners used with vehicle air bag systems by providing a unique plastic fastener assembly for use with the air bags that provides easy installation, advantageous locking features, and a large area of communication between the vehicle structure and the fastener.
SUMMARY OF THE INVENTION
In one aspect of the invention, a fastener for attaching air bags to a vehicle structure provides a secure attachment of the air bags to a vehicle structure and a releasable strap that allows the air bags to properly deploy. The invention results in a serviceable attachment that is easy to install, provides high retention features, and is resistant to the generation of rattles and other noises. In addition, the fastener of the invention reduces the likelihood of partially installed fasteners and improves the visual inspection of the fastener to ensure proper installation.
In another aspect, the method of attaching the air bag to the vehicle of the present invention eliminates the need for metal inserts by providing a large interference between the vehicle structure and a rigid portion of the plastic fastener. The invention also incorporates a technique of locking the fastener in this position to prevent it from being disengaged, and a technique for releasing this lock if needed for servicing. The attaching method of the invention simplifies assembly of the air bag system by using a hook portion that may be quickly installed to the vehicle and will support the system while allowing any positional adjustments to be made prior to locking the fastener to the vehicle.
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a side view of an exemplary embodiment of a fastener of the present invention.
FIG. 2 illustrates a perspective view of the fastener assembly of an embodiment of FIG. 1 .
FIG. 3 illustrates a side view of features of the fastener assembly of an embodiment of the present invention.
FIG. 4 illustrates a perspective view of the hook and pin catch features of the fastener assembly of an exemplary embodiment of the present invention.
FIG. 5 illustrates a perspective view of the pin of an embodiment of the present invention.
FIG. 6 illustrates a side view of the pin of FIG. 5 .
FIG. 7 illustrates a perspective view of an air bag assembly, including an embodiment of the present invention.
FIG. 8 illustrates a perspective view of an air bag assembly, including an embodiment of the present invention, prior to attachment to an automobile.
FIG. 9 illustrates a perspective view of an air bag assembly, the hook of an exemplary fastener inserted into an automobile structure.
FIG. 10 illustrates a perspective view of an air bag assembly, the hook of an exemplary fastener inserted into an automobile structure and slid into the engaged position.
FIG. 11 illustrates a perspective view of a fully installed air bag assembly according to an embodiment of the present invention.
FIG. 12 illustrates a perspective view of a service notch of an exemplary fastener on a fully installed air bag assembly according to an embodiment of the present invention.
FIG. 13 illustrates a perspective view of a fastener with a wide base and shows the attachment of an air bag tab according to an embodiment of the invention.
FIG. 14 illustrates a perspective view of a fastener with a wide base and shows the attachment of an air bag tab according to an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention may be embodied in many forms. Referring to the Figures, there are depicted various aspects of the invention. An embodiment of the present invention includes a fastener 10 adapted for use in automobile air bag attachment systems, for example. Referring to FIGS. 1 and 2 , the fastener 10 comprises a base 13 having a planar surface and a hook 11 and pin 12 to secure the base 13 to a vehicle. The hook 11 may be mounted to the base 13 such that the hook is disposed on the underside, or bottom surface, of the base 13 . The pin 12 may be disposed adjacent to the hook 11 and configured to slide through an aperture 28 ( FIG. 4 ) in the base 13 defined by inner walls configured to accommodate the outer dimensions of the pin 12 . The assembly and installation of the fastener 10 and its components to the vehicle is described below. It is noted that the fastener 10 may be made as an integral component or assembled from the individual elements described herein. For example, in an embodiment, the pin 12 may be made as an integral component with the hook 11 and the base 13 to provide a one-piece component.
The fastener 10 may include a strap 14 made of a woven material, or any other acceptable flexible material. The remaining elements of the fastener may be made of a resilient plastic or other suitable material having substantial structural integrity. The fastener 10 further defines a mating end 30 that aids in securing the air bag to the vehicle.
As exemplified by FIG. 9 , the fastener 10 may be attached to an air bag 25 by wrapping the air bag within the strap 14 and snap-fitting the end 30 to a strap retainer 15 disposed on the top surface of fastener base 13 . In one embodiment, the strap retainer 15 is configured to form flexible fingers that form an opening to receive and retain the mating end 30 of the strap 14 . The strap retainer 15 may be made of a material that is sufficiently flexible to be displaced outwardly from the force applied to insert the mating end 30 during installation and to expel the mating end during air bag deployment, yet rigid enough to retain the mating end 30 during standard operation of the vehicle. In alternative embodiments, the strap retainer 15 and the mating end 30 of the strap may define various shapes and other configurations to tailor the releasing force required to release the end 30 from the retainer 15 to the particular application requirements. For example, the strap retainer 15 may comprise a shape that extends out substantially beyond the surface of the base 13 . In one aspect of the invention, two straps 14 may be attached to the fastener 10 , each strap wrapping around opposite sides of an air bag and connecting, for example, in the middle, with one strap ending in a strap retainer 15 and the other in a mating end 30 .
In an exemplary embodiment, the air bag 25 may also be attached to the fastener 10 in the manner depicted in FIG. 13 . As shown in FIG. 13 , when an air bag is rolled up or folded and ready for installation, it may include one or more tabs 31 each defining a hole 32 to provide attachment to the fastener 10 . In this embodiment, the tab 31 may slide through a slot 33 in the base 13 and then be placed over the hook 11 . Once the assembly is installed to the vehicle, the airbag tab 31 may be held between the main hook 11 and the vehicle structure, thereby providing a secure attachment.
In an alternative aspect, the air bag 25 may be attached to the fastener 10 in the manner depicted in FIG. 14 , which is similar to the attachment shown in FIG. 13 , with the additional use of one or more pegs 34 on the base 13 that will engage the tab 31 . The pegs 34 may hook and hold the tab 31 of the air bag 25 to the fastener 10 to further secure the tab 31 to the fastener. Similar to the embodiment of FIG. 13 , the tab 31 may slide through the slot 33 in the base 13 and then may be placed over the hook 11 . Once the assembly is installed to the vehicle, the tab 31 may be held between the hook 11 and the vehicle structure and by the pegs 34 .
As described above, there may be two attachments between the airbag 25 and the fastener 10 . One may be the air bag tab attachment described above and shown in FIGS. 13 and 14 , and the second may be the strap 14 and strap retainer 15 holding the airbag in place until the airbag deploys. Once attached to the air bag, the fastener 10 of the invention may then be shipped as part of the air bag assembly. Typically, an air bag assembly will contain several fasteners 10 to attach at different locations within the vehicle.
Referring to FIGS. 3 and 7 - 11 , to install the air bag fastener assembly of an embodiment of the invention to a vehicle, the hook 11 is inserted into an existing mounting area, or hole 42 , in the vehicle structure 40 . This is achieved by an engagement area 16 ( FIG. 3 ) that is formed between the surface 17 of the hook 11 and the bottom surface of the fastener base 13 . The engagement area 16 is the opening to receive the wall of the vehicle structure 40 . In other words, as installed, the wall of the vehicle structure 40 will be positioned between the surface 17 and the bottom surface of the fastener base 13 . The surface 17 may further include a lead-in ramp disposed at the end of the surface 17 to facilitate the insertion of the wall of the vehicle structure between the surface 17 and the bottom surface of the fastener base 13 by providing a larger area into which to initially engage the vehicle structure wall edge.
After the hook 11 is installed on the vehicle structure, the pin 12 may then be inserted through the aperture 28 in the base 13 . This is accomplished by depressing the pin 12 from a disengaged position ( FIGS. 9 and 10 ) above the base to an engaged position ( FIGS. 11 and 12 ) wherein the underside of pin head 19 is in substantial communication with the top surface of the base 13 . The pin head 19 , illustrated in FIG. 5 , is defined by a planar element disposed on top of and normal to the pin shank 20 , having a lip portion extending outwardly from all sides beyond the outer diameter of the pin shank to prevent the pin 12 from sliding completely through the base 13 .
Referring to FIGS. 5 and 6 , in aspects of the invention, the pin 12 may further define pre-install tabs 21 , tightening ramps 22 , a locking tab 23 , a service notch 24 , or a combination thereof. The pre-install tabs 21 may be disposed at the lower end of opposing sides of the pin shank 20 . When the pin 12 is in the disengaged position the tabs 21 are configured to be retained in pin catches 18 ( FIG. 4 ) formed in the base 13 and defined by the hook 11 . The pin catches 18 are configured to retain the tabs 21 and thus the pin 12 in a disengaged position to prevent obstruction by the pin 12 during certain installation steps. As the pin 12 is depressed or moved to an engaged position and enters the hole 42 in the vehicle structure 40 (as illustrated by FIGS. 10 and 11 ), tightening ramps 22 ( FIG. 5 ), disposed primarily vertically along one face of the pin shank 20 and generally normal to the pin head 19 , may provide a slight interference with the hole 42 in the vehicle structure 40 to ensure a snug and rattle-free engagement. The tightening ramps 22 may be wedge shaped, for example, on the pin shank 20 , such that the width of the top of the shank is somewhat greater than the width of the bottom of the shank. The tightening ramps 22 may be flexible or elastic in an embodiment, or in an alternative embodiment, may be of a non-flexible construction.
As the pin 12 becomes fully seated, in an aspect of the invention, a locking tab 23 , parallel to and disposed between tightening ramps 22 , engages the hole 42 in the vehicle structure 40 to secure the fastener assembly to the vehicle (as illustrated by FIG. 11 ). The locking tab 23 may be a flexible tab that moves inward upon assembly and then snap-back during final installation, or the tab can be slightly resilient or otherwise configured to allow insertion of the pin and yet grab or engage the underside of the vehicle structure 40 upon final installation. In an alternate aspect, the pin 12 catches in the base 13 via the pin catches 18 to secure the fastener assembly to the vehicle.
Should replacement of any part of the assembly be necessary, an embodiment of the invention includes the use of a service notch 24 ( FIGS. 5 and 12 ). The notch 24 may be formed in the pin head and may define an opening above the locking tab 23 to allow a tool, such as a small screwdriver or other similar tool, to be inserted therein to release the locking tab 23 and pry up the pin head 19 . In another aspect, the notch 24 is located in the base 13 , defining an opening such that a small tool may be inserted to release the pin locking tab 23 that is adjacent to the base when the pin is in a fully engaged position. When the pin 12 is returned to the disengaged position, the hook 11 can then be removed. For some applications, serviceability may not be required and the service notch could be eliminated.
It is important to note that if the hook 11 is only partially installed in the hole in the vehicle structure ( FIG. 9 ), the result will be interference between the pin shank 20 and the vehicle structure, preventing the pin 12 from being driven through the hole. Therefore, a simple visual check to insure that the pin 12 is fully seated ( FIG. 11 ) provides confidence that the part is properly installed. This verification feature is an exemplary advantage of the present invention.
When the air bag 25 deploys, the strap retainer 15 releases the end 30 at a predetermined force and the end 30 of the strap 14 is forced out of the way. The mounting configuration between the fastener assembly and the vehicle structure, described above, results in a secure attachment of the fastener to the vehicle that prevents the fastener from breaking free from the vehicle structure during air bag deployment. In an alternate embodiment, an air bag may be affixed to the fastener without the use of a strap. While the invention has been described in connection with an air bag system, it should be understood that the exemplary fastener 10 may be used to secure or capture any number of different structures and may be used in numerous other applications.
Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
Various features of the invention are set forth in the following claims.
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The invention relates to fasteners adapted for use in automobile air bag attachment systems. The fastener comprises a hook to engage a vehicle structure during installation and a pin to lock the fastener in place. Advantageously, the hook portion may be quickly installed and will support the air bag assembly while allowing any positional adjustments to be made prior to locking the fastener by depressing the pin until it is fully engaged in the vehicle structure. An embodiment of the invention incorporates both a locking method to prevent the fastener from being disengaged and a method of releasing this lock if needed for servicing. Another aspect of the invention provides a method for reducing the likelihood of improperly installed parts by preventing locking when the fastener is in a partially installed configuration.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application 60/544,289, filed Feb. 12, 2004 herein incorporated by reference. This application is also related to U.S. Pat. No. 6,772,603, issued Aug. 10, 2004, and U.S. patent application Ser. No. 10/716,060 filed Nov. 18, 2003, both herein incorporated by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made with Government support under Contract No. DE-AC05-00OR22725 awarded to UT-Battelle, LLC, by the U.S. Department of Energy. The Government has certain rights in this invention.
TECHNICAL FIELD
The field of the invention is methods and apparatus for cooling of electrical devices and electronic components using vapor compression air conditioning systems in large systems such as an electric or hybrid vehicle.
DESCRIPTION OF THE BACKGROUND ART
For vehicles using electric motors and power electronic inverters, two-phase cooling with the coolant changed from the liquid phase to the vapor phase is far more effective than using single-phase such as liquid to liquid heat transfer. The significant latent heat associated with the two phase heat transfer is the reason for making two-phase cooling attractive. This type of cooling addresses the need for increased power density and associated higher heat fluxes in inverters and traction drive motors.
There are two cooling liquids available in an internal combustion engine vehicle. One is the 105° C. ethylene glycol/water supply obtained from the radiator. The other one is the 85° C. transmission oil. Strictly speaking, there is also refrigerant at high pressure available for passenger compartment air conditioning. Most people with the experience of their expensive household air-conditioning bills would have an impression that cooling the motors and inverters with a technology that is related to an air conditioning system would be impractical and expensive. This invention teaches that such a negative impression is not necessarily true when the floating-loop system is used to cool the motors and inverters in conjunction with the air-conditioning system of a vehicle.
The cooling of various loads in a vehicle is currently conducted in a piece-meal fashion. Separate cooling systems are used for the interior, the motor, the electronic devices, etc. To date, innovations in the thermal management of semiconductor devices utilized in power electronics have been relatively limited. Devices dissipating large quantities of heat have traditionally been restricted to passive cooling techniques, channel cooling, solid heat sinks, or fans. With the advent of larger, faster, higher current semiconductors efficient cooling methods are required to dissipate ever increasing densities of waste heat. It is estimated that 55% of electronic product failures are due to excessive temperatures. Universities and industry are currently working to develop new methods to provide thermal management to circuit board assemblies as well as individual silicon dies. Promising new technologies being examined include immersion, jet impingement, and spray cooling. Dielectric fluids with high heat capacities and advantageous electrical characteristics are being investigated to work with these new “wet” technologies. New thermosyphon cooling techniques are also beginning being applied to electronics at both board and individual chip levels.
A method of cooling silicon chips is being researched at Purdue University wherein semiconductors are immersed in a dielectric which vaporizes as the chips increase in temperature. The vapor condenses as it rises and is cooled by the water pipe, changes phase back to a liquid, and drops back into the pool. The temperature difference between the vapor and the liquid is negligible. For a lower vapor temperature, the water-cooled heat exchanger for a given heat extracted from the multichip modules is comparatively large.
Semiconductors are also being cooled through jet impingement. This technique, as well as spray cooling, is presently being investigated by multiple universities and industrial sources. In both cases the liquid is typically vaporized, cooled, returned to a liquid state and then recirculated.
A thermosyphon assembly developed by Hewlett Packard is utilized to implement a two-phase liquid cooling system by indirect contact with electronics. In this system the density difference between the liquid and vapor creates a pressure head, which drives the flow through the loop, and as such no additional driving force is needed. Hewlett Packard's assembly reportedly dissipates 80 W of heat from the PC processor.
Hewlett Packard has also expanded their inkjet printer technology to thermal management applications using phase change cooling. Using their existing inkjet knowledge-base they are able to precisely target specific areas of chips as well as control flow volume and rates. This technique allows spatial thermal control onto specific regions of the chip according to its heat level.
Research is also being performed in spray cooling semiconductor technologies at UCLA. Tests have been performed on cooling IGBT's with results of up to 34% improvement seen in their power handling capabilities. Water is being utilized as the coolant in these systems with the semiconductors being coated with a conformal dielectric. Additionally, UCLA's technology involves the construction of the nozzle array from silicon by reactive ion etching.
Isothermal Systems Research is developing thermal management of enclosed electronics at small system levels. Their thermal management applications also include the cooling of individual electronic devices.
The Laboratory for Physical Sciences located adjacent to the University of Maryland's College Park Campus, is a facility where university and federal government personnel collaborate on research. Faculty and students from the UMCP Departments of Physics, Electrical and Computer Engineering, and Materials and Nuclear Engineering conduct research at the LPS laboratories in various fields. The Thermal Management group at LPS is currently developing advanced spray cooling techniques for high-performance computing platforms. Their work includes individual chip cooling as well as circuit board and system level cooling.
Other companies are currently developing and marketing immersion and spray cooling thermal management systems. Modine Manufacturing, which acquired Thermacore in 2001, markets a broad range of loop thermosyphon and heat pipe cooling solutions to military and industrial users at both system and board levels. Heat pipe technology consists of a vacuum tight envelope, a wick structure and a working fluid. The heat pipe is evacuated and then back-filled with a small quantity of working fluid, just enough to saturate the wick. The atmosphere inside the heat pipe is set by equilibrium of liquid and vapor. As heat enters at the evaporator, this equilibrium is upset generating vapor at a slightly higher pressure. This higher pressure vapor travels to the condenser end where the slightly lower temperatures cause the vapor to condense giving up its latent heat of vaporization. The condensed fluid is then pumped back to the evaporator by the capillary forces developed in the wick structure. This continuous cycle transfers large quantities of heat with very low thermal gradients. A heat pipe's operation is passive, driven only by the heat that is transferred.
Thermacore is expanding their heat pipe cooling applications by embedding heat pipes into heatsinks for use under power semiconductors. For example heat pipes were embedded under each of eight power amplifier modules. The heat pipes were 0.375″ in diameter flattened into grooves in the heat sink base with a thermal epoxy at the interface. This approach reduced the thermal resistance of the heat sink by 50%. Thermacore's cooling designs specifically geared towards power applications include loop thermosyphons where the circuit board is essentially immersed in the coolant and vapor chambers.
A vapor chamber is a vacuum vessel with a wick structure lining the inside walls that is saturated with a working fluid. As heat is applied, the fluid at that location immediately vaporizes and the vapor rushes to fill the vacuum. Wherever the vapor comes into contact with a cooler wall surface it will condense, releasing its latent heat of vaporization. The condensed fluid returns to the heat source via capillary action, ready to be vaporized again and repeat the cycle. The capillary action of the wick enables the vapor chamber to work in any orientation with respect to gravity. A vapor chamber heat sink consists of a vapor chamber integrated with cooling fins, pins, etc. Due to the way the vapor chamber operates, the heat source can be placed anywhere on the base without affecting its thermal resistance. In addition, there can be multiple heat sources dissipating the same or different amounts of power. The rate of fluid vaporization at each source will stabilize and the vapor chamber will be nearly isothermal. Thermacore is utilizing this technology in the cooling of power semiconductors.
The cooling approaches described above are solving thermal problems in a piece-meal fashion. This invention looks into the cooling and heating of the hybrid, fuel cell based, and full electric vehicles from a system approach. By doing so, individual components in the system may carry multiple functions. This results in a lower cost, smaller volume, and higher efficiency system.
SUMMARY OF THE INVENTION
A floating loop vehicle component cooling and air-conditioning system is taught comprising at least one compressor for compressing cool vapor refrigerant into hot vapor refrigerant; at least one condenser for condensing said hot vapor refrigerant into hot liquid refrigerant by exchanging heat with outdoor air, at least one floating loop component cooling device for evaporating said hot liquid refrigerant into hot vapor refrigerant, at least one expansion device for expanding said hot liquid refrigerant into cool liquid refrigerant, at least one air conditioning evaporator for evaporating said cool liquid refrigerant into cool vapor refrigerant by exchanging heat with indoor air; and piping for interconnecting components of said cooling and air conditioning system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pressure vs. enthalpy diagram of a vapor compression cycle in the invention.
FIG. 2 is a schematic diagram showing elements of an embodiment of the invention.
FIG. 3 is a schematic of a flooded jacket heat exchanger embodiment of the invention.
FIG. 4 is a schematic of distributor jacket heat exchanger embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , the pressure versus enthalpy properties of a refrigerant for a refrigeration cycle is plotted. Starting from the upper left corner of the cycle, the refrigerant liquid at a high pressure P 2 and high temperature, T cond , flows through an orifice or a capillary reducing its pressure to P 1 . The vertical drop at the left-hand side of the cycle indicates a constant enthalpy process. The lower left corner of the cycle shows the beginning of the expansion process taking place in the. evaporator that gradually changes the liquid to vapor. The evaporator has a lower pressure P 1 and a lower temperature T evap . When the refrigerant in the evaporator absorbs the heat the enthalpy of the refrigerant increases, as represented by the bottom horizontal line. At the lower right corner of the cycle the refrigerant enters a compressor. The refrigerant is compressed into a high-temperature vapor that follows a constant entropy line. At the upper right corner of the cycle the refrigerant starts to dissipate its heat in a condenser and gradually changes its phase to a liquid. This is indicated by the upper horizontal line of the cycle, with the process moving to the left.
The high energy requirement of the compressor of a conventional air conditioning system is mainly caused by the pressure difference, P 1 −P 2 that the compressor has to overcome in order to produce a low temperature at the evaporator side. For cooling motors and inverters the liquid at the condenser side temperature is cold enough. Therefore, it is not necessary to have a significant pressure difference between the evaporator and condenser thus the instant invention only requires a very small pump or fan to move the fluid through the floating two-phase cooling sub-system. Whereas, a thermosyphon depends on liquid weight for the circulation and this requires a level installation. The cooling density of the thermosyphon is not high, i.e. a low heat flux per unit volume, and also would require separate cooling and condensing components be added to the system. The technology given in this invention overcomes the problems of the thermosyphon but retains its advantage of low power consumption. FIG. 1 shows the floating loop pressure-enthalpy relationship for the subject invention configurations with a liquid pump or a vapor blower. The pressure P 4 is very slightly above the P 2 /T cond line, and this indicates use of a small liquid pump in the floating loop to move the fluid. P 3 is very slightly below the P 2 /T cond line, indicating the system uses a vapor blower to move the fluid through the loop. In either case, the differential pressure (P 4 −P 2 , or P 2 −P 3 ) is very small, which indicates a low energy requirement to operate the additional “floating” cooling loop.
FIG. 2 shows an embodiment of the system of this invention. The refrigerant vapor compression floating loop 20 is used to cool the integrated motor/inverter 21 and associated electronic components by tapping into hot liquid refrigerant at the refrigerant reservoir 29 and using an optional pump 24 to pump the hot liquid refrigerant through a heat exchanger as shown in FIGS. 3 and 4 . An optional level sensor 22 and liquid level cutoff valve 23 controls the liquid refrigerant level in the heat exchanger. An optional floating loop blower 25 pumps the refrigerant vapor into the vapor compression cycle. The heat from the integrated motor converter 21 evaporates the hot liquid refrigerant thereby delivering hot vapor refrigerant into the vehicle air-conditioning system. The air-conditioning compressor 26 pumps the hot vapor through an optional unidirectional valve 27 and into the condenser 28 where the heat is dumped to atmosphere resulting in hot liquid refrigerant. The hot liquid refrigerant collects in the refrigerant reservoir 29 and a portion of the hot refrigerant liquid not used in the floating loop passes through a valve 33 and is expanded in an orifice 30 or other suitable expansion device to generate cool liquid refrigerant for the evaporator 31 . Heat is transferred to the refrigerant in the evaporator 31 thereby cooling the indoor or vehicle cabin air and generating hot vapor refrigerant that passes through pressure controls 32 into the suction side of the air-conditioning compressor 26 . All devices are interconnected using refrigerant piping 34 .
FIG. 3 is an example of a flooded jacket heat exchanger used to cool the integrated motor/inverter 40 . Hot liquid refrigerant 46 is flooded into a jacket at least partially surrounding the integrated motor/inverter 40 . A refrigerant level sensor 41 controls the amount of liquid refrigerant in the jacket. Power electronic switching dies 43 are also liquid refrigerant cooled. Capacitors 45 are outside of the pressurized cooling zone but proximate the heat exchanger thereby receiving conductive cooling from the heat exchanger jacket. Power and control wiring passes through a terminal 44 . An optional thermal coating 42 is applied to the integrated motor/inverter 40 .
FIG. 4 is another embodiment using a distributor jacket with cooling tubes as the heat exchanger for cooling the integrated motor/inverter 50 . Hot liquid refrigerant 56 is flooded into a distributor jacket at least partially surrounding the integrated motor/inverter 50 . A refrigerant level sensor 51 controls the amount of liquid refrigerant in the jacket. Power electronic switching dies 53 are also liquid refrigerant cooled. Capacitors 55 are outside of the pressurized cooling zone but proximate the heat exchanger thereby receiving conductive cooling from the heat exchanger. Power and control wiring passes through a terminal 54 . An optional thermal coating 52 is applied to the integrated motor/inverter 50 .
FIGS. 4 and 5 show motor/inverter geometries that provide an integrated fluid chamber, allowing drain-back of liquid to the power inverter. This technique provides liquid submersion of the power electronics dies for cooling during and after the initial startup of the system when no refrigerant is yet flowing.
For total cooling management, instead of a piece-meal approach, a central compressor, condenser, and refrigerant reservoir are used. The refrigerant from the reservoir is distributed through different orifices or capillary tubes and valves to various objects. The object can be an inverter, a motor, an evaporator such as the evaporator for the interior air conditioning, etc. The back pressures of the objects are individually regulated by the pressure controller for maintaining the proper temperature of each object.
Unique technical features of the invention include: 1) floating refrigeration loop technology where lower amounts of energy are needed for cooling the motors and inverter/converters; 2) a total thermal management system that uses a floating refrigeration loop floating within the conventional air-conditioning refrigeration loop wherein components and refrigerant are shared; 3) the motors and inverter/converters are integrated and cooled in the floating loop. For example, it is possible to integrate the motor and the inverter/converter wherein the frame of the motor is used as an evaporator. Three zones of cooling (i.e. liquid, vapor, and non-pressurized zones) are used for cooling. The non pressurized zone is used to cool the capacitors and other inverter/converter components that are not suitable for the pressurized environment; 4) a total thermal management system that shares a compressor and condenser for cooling multiple objects at different temperatures; 5) a total thermal management system that controls fluid flow and back pressure to regulate temperature for the specific component; 6) the liquid level is controlled using a level sensor; 7) the level sensor can be optional if the optional pump is used in the floating loop when no small compressor is included in the floating loop; 8) the system can be operated when the vehicle is tilted.
While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope.
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A floating loop vehicle component cooling and air-conditioning system having at least one compressor for compressing cool vapor refrigerant into hot vapor refrigerant; at least one condenser for condensing the hot vapor refrigerant into hot liquid refrigerant by exchanging heat with outdoor air; at least one floating loop component cooling device for evaporating the hot liquid refrigerant into hot vapor refrigerant; at least one expansion device for expanding the hot liquid refrigerant into cool liquid refrigerant; at least one air conditioning evaporator for evaporating the cool liquid refrigerant into cool vapor refrigerant by exchanging heat with indoor air; and piping for interconnecting components of the cooling and air conditioning system.
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BACKGROUND OF THE INVENTION AND PRIOR ART
This invention relates generally to turn-off circuits for preventing phosphor burns on the viewing screens of CRTs and particularly to a turn-off circuit used in connection with non-shadow mask projection type CRTs supplied from switched mode power supplies.
A CRT (cathode ray tube) includes an electron gun situated at one end of an evacuated envelope for developing an electron beam that is accelerated toward a light-emitting phosphor target or screen comprising the other end of the CRT. The screen is generally deposited on the inner surface of the CRT faceplate. Magnetic deflection windings, or electrostatic deflection plates, are suitably disposed about the CRT neck and supplied with appropriate horizontal and vertical deflection voltages for deflecting or "sweeping" the electron beam in a pattern over the phosphor screen to define a rectangular-shaped raster. The electron beam is modulated in intensity during its deflection to develop the video display. In direct view color CRTs, a foraminous mask is interposed between the electron gun and the screen for "shadowing" different colored light emitting phosphors from all but their associated electron beams. As is well-known the foraminous mask, or shadow mask as it is commonly referred to, is impacted by and therefore absorbs much of the beam energy. Consequently, phosphor burn due to excessive beam energy in direct view color CRTs is not as serious a problem as it was with monochrome CRTs.
So-called projection television receivers commonly use three independent, different colored CRTs. For example, the color CRTs may comprise individual red, blue and green light emitting types. In such tubes, no shadow mask is required. Rather, three independent images are generated, one in each of the basic colors red, blue and green, and combined, either by direct projection or through a mirror system, to form a resultant color image on a display surface. In these systems, the sources (color CRTs) are small and the final image is large, which requires that the color tubes be driven hard to generate the large light outputs required in projection applications. The combination of large electron beam current and the lack of a shadow mask, makes such projection tubes prone to phosphor burn by the undeflected electron beam in the event appropriate safeguards are not taken when turning the set off. The problem is compounded with the use of switched mode power supplies in which the power supply is on continuously, with the load circuits being switched as needed. The significance of the problem is apparent when considering the high cost of such CRTs and the relative ease with which phosphor burn may occur.
It is conventional practice, when turning off a CRT, to blank the video to cut off the electron beam. In that instance, there is no undeflected electron beam to come to rest at a central spot on the CRT screen and the problem of phosphor burn is not present. However, should the blanking circuitry fail or, as is more likely, should the blanking circuitry operate ineffectively, there is the danger that an electron beam of significant energy may be present when the deflection circuits collapse the raster to a very small area. Hence the problem of phosphor burn is ever present.
Difficulties may also arise should operation of the blanking circuit be compromised, which can occur for a number of reasons. One is that the CRT G2 grid voltage may be very high and cause a shift in the tube cut-off characteristic. It is very common for service personnel to adjust the G2 voltage to its maximum to compensate for a loss in tube brightness due to low cathode emission. Such a tube may experience impaired blanking due to the high G2 voltage and make it prone to phosphor burn upon turn off despite a fully functional and operating blanking circuit. Another problem may be inadvertently introduced by the presence of a safety circuit that is often built into projection TVs to prevent overheating of the CRTs. In some receivers, the CRTs are driven so heavily (to obtain brightness levels suitable for projection viewing) that their frit seals, that is, the glass bonds between the CRT faceplate and funnel may fail because of the differential thermal expansion between the relatively thick faceplate and relatively thin funnel. A high electron beam shut off circuit may be used to turn off the receiver. Turning off the receiver under these conditions may result in compromising the effectiveness of the blanking circuit and pose the threat of phosphor burn. Further, such shutdown circuits may be inadvertently activated by misadjustment of the receiver controls by a serviceman. Also, most projection TV receivers and monitors include a "setup" switch to enable the cut off of the various CRTs to be appropriately established. Inadvertently turning the receiver off while in the setup mode can also seriously compromise the blanking circuit and cause phosphor burn. Accordingly, there is a need in the art for a turn-off circuit for a projection type television CRT that precludes the possibility of phosphor burn.
OBJECTS OF THE INVENTION
A principal object of the invention is to provide a novel turn-off circuit for a CRT.
Another object of the invention is to provide a video system that minimizes the likelihood of CRT phosphor burn on turn-off.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects and advantages of the invention will be apparent upon reading the following description in conjunction with the drawing, the single figure of which is a partial block, partial schematic diagram of a CRT turn-off system constructed in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the single figure of the drawings, a projection TV receiver includes a control block 10, indicated as containing a microprocessor, that supplies an ON or an OFF signal to the base of a NPN transistor 14. The base of transistor 14 is coupled to ground through a capacitor 12 whereas its emitter is connected directly to ground. The collector of transistor 14 is connected through a resistor 16 to the base of a PNP transistor 18 having an emitter that is connected to the 12 volt DC standby B+ voltage of a switched mode power supply 30. The collector of transistor 18 is connected to ground through a relay coil 20 which, as indicated by the dashed lines, operates a set of contacts 22. The collector is also connected through a resistor 24 to an ON/OFF input terminal 29 of power supply 30. Input terminal 29 is coupled to ground by the parallel combination of a resistor 26 and a filter capacitor 28. Power supply 30 is connected by means of an AC line cord and plug 32 to a conventional source of household power. Power supply 30 includes both a switched low B+ voltage output terminal 33 and a switched high B+ voltage output terminal 35. The switched high B+ voltage (130 volts DC) is supplied to one contact of contact set 22. The other contact of contact set 22 is connected to a horizontal deflection circuit 36 and to ground through a capacitor 34. The switched low B+ voltage (12 volts DC) is also supplied to horizontal deflection 36. Horizontal deflection circuit 36 is in all respects conventional and includes suitable transistors and transformers for developing horizontal deflection voltages for application to a horizontal deflection winding 44 in a suitable yoke (not shown) that is positioned on the neck of a CRT 42. As is well-known, the 12 volt DC is the low B+ voltage driving the various deflection circuit transistors that control the development of the deflection voltages. Horizontal deflection circuit 36 is also coupled to a high voltage circuit 38 where, in a well-known manner, the high (25-30 kilovolt) voltage is developed for application to CRT 42. Finally, a source of video input 40 is shown coupled to the neck of CRT 42, it being understood that the electron gun structure in the tube is omitted for the sake of clarity.
In operation, switched mode power supply 30 is either on, or in standby. The 12 volt standby B+ potential is therefore present before the receiver is turned on. The 12 volt B+ for low level drive, however, is switched and is therefore not present when the receiver is in the standby mode. The actual construction and operation of switched mode power supply 30 is well-known in the art and will not be described herein. Suffice it to say that the 12V switched B+ and the 130V switched B+ are turned on by application of the ON voltage (1.79 volts) at input terminal 29 and are turned OFF when that voltage is removed. Control microprocessor 10 supplies a 1.7 volt ON signal to the base of transistor 14 to accomplish the switching. It should be appreciated that in a conventional circuit, that is, one not utilizing the invention, control microprocessor 10 would directly supply input terminal 29 of power supply 30.
The 1.7 volts at the base of transistor 14 drives transistor 14 conductive which, in turn, forward biases transistor 18 and energizes relay winding 20. Contact set 22 is closed and applies the 130 volts DC from power supply 30 to horizontal deflection circuit 36. (The full application of this voltage is delayed for a short period of time due to charging of capacitor 34.) The potential at the collector of transistor 18, while also delayed somewhat by the charging of capacitor 28, also causes power supply 30 to supply 12V B+ for the low voltage drive circuits in horizontal deflection circuit 36. Thus the necessary deflection voltages for deflection winding 44 and the high voltage for CRT 42 are produced. The initial delay in turning on CRT 42 is not objectionable nor is it harmful since the heater in the CRT takes time to reach its operating temperature at which it emits significant quantities of electrons.
Upon shutdown, however, a different result obtains. Responsive to a suitable signal from control 10, transistor 14 is cut off and drives transistor 18 non-conductive. Relay 20 is immediately de-energized and opens contact set 22, which interrupts the 130 volt DC supply to the horizontal deflection circuit 36. The potential change at the collector of transistor 18 is, however, not immediately presented to input terminal 29. It is delayed by the discharge of capacitor 28 through resistor 26, and through resistor 24 and relay winding 20. Consequently, the power supply 30 does not receive a turn-off signal until approximately 1/2 to 1 second later. The 12 volt B+ for low level drive to deflection circuit 36 is maintained and the horizontal deflection circuit continues to operate. The magnitude of the deflection and the size of the developed raster decreases since its 130V B+ operating potential is rapidly decaying as capacitor 34 discharges. Simultaneously, the high voltage developed by high voltage circuit 38 decays and the net result is that the raster size and high voltage are reduced together. The high voltage energy storage in the CRT is rapidly dissipated because the video drive and deflection system are still effective and when power supply 30 switches off the 12 volt B+ low level drive voltage, the high voltage is substantially extinguished and the beam energy is low. Thus a safe shutdown is provided for CRT 42.
The provision of the delay capacitor 34 is preferred although not required. Capacitor 34 enables the decay in the deflection and high voltages to occur at a slower rate and permits greater control of shutdown.
What has been described is a novel shutdown circuit for a CRT that eliminates the potential for phosphor burn of the CRT screen. It is recognized that numerous changes in the described embodiment of the invention will be apparent to those skilled in the art without departing from its true spirit and scope. The invention is to be limited only as defined in the claims.
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A shutdown circuit for a projection type CRT comprises a transistor switch for operating a relay, responsive to a turn-off signal, to immediately break the high B+ operating voltage connection to a horizontal deflection system. A switched mode power supply is supplied with the turn-off signal, after a delay caused by a resistance-capacitance circuit, for shutting down the low voltage drive voltage to the horizontal deflection system after occurrence of the turn-off signal.
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This invention claims priority of Provision Application Ser. No. 60/057,951 filed Sep. 5, 1997.
In accordance with the present invention, a universal golf club securer and organizer includes two singular support bars upon which are attached numerous individual resilient clips for securing the head of a single golf club. Each golf club head securer is made of a strong yet resilient material which both holds the golf club firmly in place and allows easy insertion and extraction of a golf club head. Further, the golf club head securer is molded to fit any ironhead golf club. The minor variations between sets of golf clubs in size and contour are accommodated by the flexible nature of the resilient securing device.
In the preferred embodiment of the invention, the two singular support bars are made of a relatively stiff material which has been molded to be attached to a bag at an angle of approximately fifteen degrees from front to back. In this configuration, when the golf clubs are inserted into their proper securing device, the golfer is able to see each club at a glance.
A separate feature, a central holding unit made of the same relatively stiff material as the frame has other resilient clips which may be used to hold additional golf clubs such as the woods and the putter. This arrangement protects the woods and the putter from damage and keeps the golf club bag in balance.
Another aspect of the present invention includes a system designed to allow attachment of the frame of the club holder to golf club bags of varying sizes. Additionally, the system is adjustable to the height of any set of golf clubs.
The preferred embodiment of the invention may also include the following additional features:
1. The support bars and the securing devices may come in a variety of different colors.
2. The support bars and the securing devices may be integral with a golf club bag as one unit, or readily removable from the bag and transferred to a second bag.
3. The securing devices may have numbers imprinted thereon which correspond to the specific golf club number.
4. The frames may be made in different sizes and shapes to accommodate non-standard golf club bag openings, including circular.
Advantages of the present invention include the fact the clubs are secured and held in a manner that protects the clubs both during usage and during travel. Since the clubs are suspended either longitudinally across the bag mouth or in the separate central holder, the bag is always kept in balance. Another advantage is the organization of the clubs which the invention provides. This organization, combined with the physical angle-like form, allows for easy location and easy inventory of the clubs. Further, since each clubhead is protected and not allowed to move freely or rotate in the bag, the invention reduces or eliminates the noise typically made by clubs rattling and banging each other when carried in a golf bag.
Other objects, features and advantages of the present invention will become apparent from a consideration of the following detailed description and from the accompanying drawings.
FIG. 1 is a perspective view of a golf bag embodying the device of the present invention.
FIG. 2 is a perspective view of the support bar, support bar clip and clubhead securers.
FIG. 3 a is a form perspective view and FIG. 3 b is a side perspective view of the rod and clamp
FIG. 4 is a perspective view of the support bar, support bar clip and club head securer adjusted to receive an angled iron.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, FIG. 1 is a depiction of a universal golf club securer and organizer 8 attached by means of rods 50 and clamps 52 to a support bar 12 of the golf bag 10 . Placing the shafts of the irons into the inner recesses of the golf club bag 10 and the heads of the golf club irons 16 into the golf club head securer 40 , the irons 14 are neatly spaced longitudinally from front to back of the golf club bag so that the irons 14 are held securely in place at all times.
Securing the clubs in place has several advantages. First, if the golf bag 10 is upset or used for long distance transportation, the clubs will remain secure and in place. Second, the club heads are protected from scratching and chipping. Third, the clubs 14 are easy to find and return to the same location because each has a proper position in the universal golf club securer and organizer 8 . This also helps with keeping a constant inventory of the clubs and reduces the likelihood that clubs will be lost.
The support bars 12 of the universal golf club securer and organizer 8 , as can be seen from FIG. 1 in a preferred embodiment, are straight tubular rods with rounded ends. Each support rod has several golf club head securers 40 mounted upon it. The head securers are attached to the support rod by the support rod clip 60 which slides along the support bar 12 allowing various configurations of the head securers. The ultimate formation of the golf club head securers 40 allows the user to see all the clubs at one time. Additionally, this configuration puts the heads in a longitudinal and angular formation which is particularly attractive.
Located in the center of the bag between the two separate singular support bars is a central inner holder 30 with clips 32 into which golf clubs such as the woods 18 and the putter 19 may be inserted. FIG. 1 shows the golf club woods 18 held in the clips 32 of the central inner holder 30 and extending above the irons 16 .
FIG. 1 is a perspective view of the universal golf club securer and organizer 8 in place in the golf bag 10 and containing a set of golf clubs 14 , 18 , and 19 . The irons 14 are held in place by contoured-like securers 40 longitudinally across the golf bag 10 . The woods 18 and putter 19 are situated within the clips 32 of the separate central inner holder 30 which is mounted to extend across the central opening 22 of the golf bag 10 . The typical diameter or width of a rim of a golf bag opening 62 may be approximately eight to ten inches. By using several rods 50 and clamps 52 (as best seen in FIG. 3) the two singular support bars may be used to fit any standard round or square shaped or sized golf bag 10 . The rods 50 and lamps 52 will be discussed in greater detail in conjunction with FIG. 3 .
The singular support bars 12 of the golf club securer and organizer is made of a relatively stiff material. In its preferred embodiment, the two singular support bars is molded out of a firm plastic or rubber material, other materials which could be effective used to make a frame include, for example, a lightweight metal or fiberglass. These materials are merely examples and are not intended to limit the scope of the invention.
The two singular support bars 12 in the preferred embodiment are approximately parallel and define a central opening 22 . However, the two singular support bars 12 may be angled symmetrically toward a lower portion 23 and be spaced further apart at an upper portion 25 of the golf bag 10 .
Each support bar 12 has at least one golf club head securer 40 mounted upon it. By inserting the locking device 44 through the bore 26 (as best seen in FIG. 2) the golf club head securer 40 is fastened to the support bar clip 60 . Alternatively, other methods of mounting, such as glues or mating recesses, known to those skilled in the art, could be used by way of illustrative examples.
Located within or extending across the central opening 22 is a central inner holder 30 . As shown, the central inner holder is attached to the lower portion 23 and upper portion 25 of the golf bag 10 . The central inner holder 30 is preferably formed of the same stiff material as the support bar 12 . The central inner holder 30 and the support bar 12 may be a single unit or may be formed separately and secured together.
The support bar 12 is attached to the rim of a golf bag 22 by a series of rods 50 and clamps 52 . In the preferred embodiment, the rods 50 (as best seen in FIG. 3) are made of a sturdy material such as steel or aluminum. The rods consist of two longitudinal portions. The portions of the rod should be long enough to allow for both the varied width of the openings of a golf bag 10 and for the varying heights of golf club sets. A set of essentially flattened hook-shape clamps 52 are provided to secure the rod 50 to the rim of the golf club bag 10 . The clamps are made of a sturdy high-strength metallic material such as engineered plastic, steel, or aluminum.
This rod 50 and clamp 52 (as best seen in FIG. 3) system of joining the golf club securer and organizer 8 to the golf bag 10 is only meant to be exemplary. Another method could involve the use of extension rings in which either several rings of uniform size or rings of the height desired are provided to be secured between the frame 20 and the rim of the golf bag 10 . In addition, the frame 20 could be permanently attached to the golf bag 10 .
FIG. 4 is a longitudinal cross-sectional view of a golf club head securer 40 and the adjacent portion of the support bar 12 . The securer is made of a resilient material which, in the preferred embodiment, is a plastic or rubber material. The upper portion of the securer 40 is an opening of the general shape of the head of a golf club iron 16 . A golf club iron is pressed into the golf club head securer 40 from above, and is held in place by the spring action of the resilient golf club head securer. The golf club head securer may be rotatably attached to the support bar clip 60 which then is attached to the support bar 10 so that the angle of the golf club head securer with respect to the support bar can be changed to allow for differences in angles in the heads of golf club irons. A bolt, screw, or other fastener 44 is inserted through the opening 26 in the base of the support bar clip 60 for rotatably attaching the clip to the support bar. The support bar clip 60 with the golf club head securer 40 may be adjusted along the support bar 12 to adequately accommodate various size golf club irons in succession.
In conclusion, it is to be understood that the present invention is not to be limited to that precisely as described herein-above and as shown in the accompanying drawings. More specifically, the support bars could take shapes other than straight (such as curved or bowed) in order to accommodate various styles of golf club bags. Further, the club holders can be of various colors or numbered for easier club identification. The materials discussed are meant to be exemplary and could be exchanged with any other material suitable for the intended purpose. Numbering on the holders corresponding to the numbers of the specific golf club could be added to the exterior or top surface of the holders. Also the contour of the fingers of the securers can be modified to hold woods or the putter or separate adapters specifically designed to hold clubs or items other than irons can also be mounted to the support bars. Accordingly, the present invention is not limited to the arrangements precisely as shown and described herein-above.
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A universal golf club securer and organizer for securing golf clubs in a fixed position in a golf bag which consists of a series of individual resilient clips having adjustable positions on a support bar thereby compensating for the width of any club in a set of golf clubs. The support bar is attached to a golf bag by means of a rod and clamp system which is adjustable to the height of any set of golf clubs.
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BACKGROUND OF THE INVENTION
[0001] Undercarriages are known that include a shock absorber having first and second elements that are slidable relative to each other, said slidable elements defining an internal volume that is partially filled with hydraulic fluid so as to leave respective first and second chambers in the ends of the slidable elements, which chambers are filled with gas under pressure.
[0002] In general, the shock absorber includes a diaphragm secured to one of the elements and presenting throttling orifices through which the hydraulic fluid is forced in the event of a shock driving the elements towards each other. Such throttling dissipates a fraction of the kinetic energy of the airplane that has led to the shock absorber being compressed.
[0003] Another fraction of the kinetic energy is absorbed by compressing the gas contained in the chambers, given that said chambers decrease in volume during a shock.
[0004] For undercarriages situated beneath the fuselage of an airplane, it is important to ensure that the undercarriages cannot break their attachment points since that would run the risk of injuring passengers or of damaging fuel tanks.
[0005] It is known that the force transmitted by a shock absorber can be limited by providing structural portions designed to buckle when the force in the shock absorber exceeds a predetermined threshold. However such systems are difficult to design, and they require any buckled structural portions to be replaced before it is possible for the airplane to take off again, and that can interfere with regular service on the line provided by the airplane and can be awkward when the airplane is located at an airport that is remote and isolated.
OBJECT OF THE INVENTION
[0006] An object of the invention is to provide a shock absorber provided with a safety device enabling the force transmitted by the shock absorber to be limited, and not requiring an immediate maintenance operation after the safety device has been triggered.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention provides an undercarriage including a shock absorber having a first element and a second element that are slidable relative to each other, said slidable elements defining an internal volume that is partially filled with hydraulic fluid so as to leave respective first and second chambers in the ends of the slidable elements, which chambers are filled with gas under pressure. According to the invention, the shock absorber includes a third chamber filled with gas and placed in series with the first chamber while being separated therefrom by a separator piston mounted to slide in sealed manner in the corresponding slidable element between an end-of-stroke abutment and the end of said slidable element.
[0008] Thus, when the pressure in the first chamber reaches a pressure equal to the inflation pressure of the third chamber, due to the shock absorber being compressed, the separator piston starts to move in such a manner that the pressures in the two chambers remain equal (ignoring the effects of the piston's friction and inertia).
[0009] The first and third chambers then behave as through they form a single chamber. The first chamber thus sees its volume increase by the volume of the third chamber, thereby tending to decrease the slope of the curve representing the force transmitted by the shock absorber, and as a result decreasing the maximum force that the shock absorber can transmit.
[0010] Thus, the third chamber represents a safety device that is very simple to implement. In addition, the separator piston itself returns to abutment when the pressure in the first chamber drops below the inflation pressure of the third chamber. The safety device of the invention therefore reinitializes itself automatically without requiring any maintenance action. Operation of the airplane is therefore not interrupted and it can continue to provide a commercial service.
[0011] Preferably, the separator piston is mounted to slide in leaktight manner on a central column having a free end that carries the end-of-stroke abutment.
[0012] In a particular aspect of the invention, the central column has a central duct opening out into the first chamber. In which case, the first chamber preferably contains a quantity of hydraulic fluid that is just sufficient to come flush with an inlet of the central duct.
[0013] In another particular aspect of the invention, the central column has an auxiliary duct opening out into the third chamber. In which case, the third chamber preferably contains a quantity of hydraulic fluid that is just sufficient to come flush with an inlet of the auxiliary duct.
BRIEF DESCRIPTION OF THE DRAWING
[0014] The invention will be better understood in the light of the following description given with reference to the figures of the accompanying drawing, in which:
[0015] FIG. 1 is a longitudinal section view of a shock absorber of the invention; and
[0016] FIG. 2 is an enlarged view of FIG. 1 level with the gas bottle.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention is applied herein to a direct type undercarriage with an integrated shock absorber mounted under the fuselage of an airplane. Clearly the invention is not limited to undercarriages of this type, and is also applicable to undercarriages having an external shock absorber, and not necessarily mounted under the fuselage.
[0018] With reference to FIG. 1 , and in conventional manner, the undercarriage comprises a main strut 1 connected to the airplane and having a rod 2 mounted to slide in leaktight manner therein. For this purpose, the strut carries a bottom bearing 3 in its lower portion with an inside surface in contact with the rod 2 , and the rod 2 carries at its top portion a top bearing 4 with an outside surface in contact with the strut 1 .
[0019] A scissors linkage 5 (of which only the ends of its two branches are visible) is mounted between the strut 1 and the rod 2 to prevent the rod 2 turning about its axis relative to the strut 1 .
[0020] At its bottom end, the rod 2 forms a fork whose branches include bores 6 for receiving the hinge pin of a rocker beam carrying a plurality of wheels (not shown). In this example, the branches of the fork extend beyond the bores 6 in order to present bores 7 for receiving the ends of brake bars (not shown) for preventing angular movement of brake rings fitted to the wheels carried by the rocker beam.
[0021] A perforated tube 8 having its top end secured to the strut 1 extends inside it and carries at its bottom end a diaphragm 9 having an outside surface that slides in leaktight manner on the inside surface of the rod 2 .
[0022] The diaphragm 9 has throttling orifices 10 and a central orifice 11 in which there extends a throttling needle 12 secured to the rod 2 via a support 13 fitted inside the rod 2 by means of a retaining ring and having through orifices.
[0023] A first separator piston 14 is mounted inside the rod 2 to slide in leaktight manner, the support 13 forming an end-of-stroke abutment for said separator piston 14 .
[0024] A second separator piston 15 is disposed inside the rod 2 to slide in leaktight manner. As can be seen more clearly in FIG. 2 , the second separator piston 15 slides on a column 16 secured to the end of the rod 2 . The column 16 has an end-of-stroke abutment 17 at its top end for the second separator piston 15 .
[0025] When the shock absorber is extended, as shown, hydraulic fluid (represented by horizontal dashes) completely fills the volume between the separator piston 14 and the diaphragm 9 , and also the annular volume extending between the outside wall of the rod 2 and the inside wall of the strut 1 , between the two bearings 3 and 4 . Hydraulic fluid partially fills the volume that extends above the diaphragm 9 .
[0026] The remainder of the internal volume of the shock absorber defines a first chamber 18 which extends between the first separator piston 14 and the second separator piston 15 , and a second chamber 19 formed by the fraction of the volume above the diaphragm 9 that is not filled with hydraulic fluid, and a third chamber 20 arranged under the second separator piston 15 . The third chamber 20 is thus disposed in series with the first chamber 18 .
[0027] The first chamber 18 is filled with nitrogen (represented by dots) at a pressure of about 120 bars, while the second chamber 19 is filled with nitrogen at a pressure of about 20 bars. The third chamber 20 is inflated to a pressure of about 180 bars, i.e. a pressure greater than the inflation pressure of the adjacent first chamber 18 .
[0028] When the shock absorber is extended, the first separator piston 14 is then in abutment against the support 13 , while the second separator piston 15 presses against the abutment 17 .
[0029] The shock absorber operates as follows.
[0030] During landing, the rod 2 is forced into the strut 1 . As it happens, hydraulic fluid is forced to pass through the throttling orifices in the diaphragm 9 . This throttling dissipates energy by internal friction in the hydraulic fluid. The quantity of hydraulic fluid passing through the diaphragm 9 decreases the volume of the second chamber 19 correspondingly, thereby compressing the nitrogen that is contained therein and increasing its pressure.
[0031] It should be observed that the fluid located above the diaphragm 9 is at a pressure that is imposed by the pressure that exists in the second chamber 19 . As for the fluid located beneath the diaphragm 9 , its pressure is determined by the resistance opposed to hydraulic fluid passing through the throttling orifices in the diaphragm 9 . When this pressure reaches the inflation pressure of the first chamber 18 , the first separator piston 14 begins to move, thereby compressing the gas in the first chamber 15 .
[0032] The nitrogen contained in the chambers 18 and 19 thus behaves like a spring delivering force that corresponds to a relationship that is substantially polytropic.
[0033] Thereafter, the rod 2 is in a position of stable equilibrium inside the strut 1 under the effect of that fraction of the weight of the airplane to which the undercarriage is subjected. In the equilibrium position, the hydraulic fluid and the nitrogen contained in the two chambers 18 and 19 are at the same pressure.
[0034] Under certain circumstances, e.g. when the airplane is unevenly loaded, or in the event of a wing undercarriage failing while landing, the central undercarriage may need to support a large fraction of the weight of the airplane, in particular a weight exceeding the limits for which it was designed.
[0035] In order to ensure that the force exerted on the undercarriage does not exceed a dangerous level, the second separator piston 15 is suitable for moving when the pressure in the first chamber 18 reaches the inflation pressure of the third chamber 20 .
[0036] When that happens, the shock absorber behaves as though the volume of the first chamber 18 had been instantaneously increased by the volume of the third chamber 20 , thereby reducing the slope of the curve plotting the force transmitted by the shock absorber, and thereby reduces the maximum force that can be transmitted via the undercarriage.
[0037] The third chamber 20 constitutes a simple safety device, enabling the maximum forces transmitted via the undercarriage to be limited.
[0038] As soon as the pressure in the first chamber 18 drops back below the inflation pressure of the third chamber 20 , the second separator piston 15 automatically goes back against the abutment 17 . The safety device of the invention thus reinitializes itself automatically so that no maintenance is needed and the airplane continues to be capable of being used normally, even after the safety device has been triggered.
[0039] The movement of the second separator piston 15 causes the pressure in the third chamber 20 to rise, such that said movement is easily detected by means of a simple pressure sensor suitable for detecting when a pressure threshold is exceeded in the third chamber 20 .
[0040] In a particular aspect of the invention, the column 16 includes a central duct 22 which opens out into the first chamber 18 , thus making it easy to inflate said first chamber from outside the strut, via an inflation valve 24 .
[0041] Another inflation valve (not shown) is placed directly on the rod 2 to enable the third chamber 20 to be inflated.
[0042] In another particular aspect of the invention, the second chamber 18 contains a small quantity of hydraulic fluid, just enough to lie flush with the top end of the column 16 , and thus the inlet of the central duct 22 . The sealing gaskets on the second separator piston 15 thus continue to be wetted by the hydraulic fluid, which prevents them from drying out. In addition, in the event of the sealing gasket of the first separator piston 14 failing, the leakage of hydraulic fluid resulting from such failure flows into the first chamber 18 . The entire leakage then spills into the central duct 22 of the column 16 because the top end of the column 16 is flush with the hydraulic fluid already present in the first chamber 18 .
[0043] Thus, by means of the central duct 22 , maintenance performed on the first chamber 18 can detect a failure of the sealing gasket of the first separator piston 14 .
[0044] Similarly, the third chamber 20 contains a small quantity of hydraulic fluid, just enough to be flush with the inlet of an auxiliary duct 23 formed in the bottom of the column 16 and closed by a bleed screw 25 . The presence of hydraulic fluid in the auxiliary duct 23 , as detected during a maintenance operation, constitutes an indication that one of the sealing gaskets of the second separator piston 15 has failed.
[0045] The invention is not limited to the particular embodiments of the invention described above, but on the contrary covers any variant coming within the ambit of the invention as defined by the claims.
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The invention relates to landing gear including a shock absorber having fist and second elements slidable relative to each other, the slidable elements defining an inside volume which is filled in part with hydraulic fluid so as to leave a first chamber filled with gas under pressure and located at the end of one of the slidable elements. According to the invention, a vessel filled with gas under pressure is housed in the end and is provided with a shutter member that is initially in a closed state and that is suitable for taking up a stable open state when the pressure in the first chamber exceeds the pressure in the vessel by a predetermined threshold amount.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lens meter for measuring the optical characteristics of a lens including spherical refractive power, cylindrical refractive power, axial angle and prism quantity and, more particularly, relates to a lens meter for measuring the additive diopter of a lens.
2. Description of the Prior Art
A known lens meter, such as "Auto Lens Meter LM-870" proposed by the applicant of the present patent application, determines the optical characteristics of a lens including spherical refractive power, cylindrical refractive power, axial angle and prism quantity on the basis of results of measurement of the locus of measuring light transmitted through the lens by a photo-detecting device. This known automated lens meter is capable of operating in an additive diopter measuring mode and of measuring the additive diopter of a progressive focus lens. When measuring the additive diopter of a lens by this known lens meter, the far viewing section of the lens is measured, the lens meter is set for the additive diopter measuring mode, the measured data of the far viewing section is stored in a memory, the lens is shifted to position the near viewing section of the lens at the measuring position, the data of the near viewing section is measured when the operator decides that the near viewing is positioned at the measuring position, and the difference between the measured data of the far viewing section and that of the near viewing section is calculated to determine the additive diopter.
The respective positions of the far viewing section and the near viewing section in the lens are determined subjectively by the operator and the correctness of the determination is dependent on the perception and experience of the operator. Generally, as shown in FIG. 12; a catalog "RS-type soft progressing focus lens" of Teijin Lens Co. Ltd., a lens as manufactured is provided with marks indicating the respective positions of the far viewing section and the near viewing section.
Therefore, the respective positions of the far viewing section and near viewing section of the lens as manufactured can be fairly accurately determined for measuring the characteristics of the lens. However, these marks are easily erasable, the marks are erased when the framed lens is wiped for cleaning and concealed marks are difficult to recognize visually. Therefore, the accurate measurement of the lens requires a skillful expert operator. Furthermore, any objective data securing correct measurement is not available.
There is known a prism thinning process as a lens processing method, called Prismatic Thinning, Allege processing and the like. The prism thinning process is for thinning a thickness of a progressive focus lens, particularly of a far viewing section of the progressive focus lens. In the method, as shown in FIGS. 13(a) and 13(b); a catalog "SEIKO P-1 Genius" of Hattori Seiko Co. Ltd., a plus-lens is applied with a down-prism process and a minus-lens is applied with an up-prism process, a progressive focus lens is thereby intended to have a thinner thickness, in any additive diopter. Since there is a tendency for a progressive focus lens to thicken and increase in weight than a standard lens, it is not comfortable to wear the framed progressive focus lens. To dissolve the above problem, mainly a far viewing section of a progressive focus lens is cut down to thin through the above a prism thinning process. Consequently, prism in a longitudinal direction of the lens of when person puts on his spectacles is included in the lens, though it is considered that the prism does not affect the lens on using.
A measuring point of a for viewing section of a lens commonly positioned, varying far lenses manufactured by each lensmaker, at an upper point about 6-10 mm from a geometric center of the lens, and the position can be determined by finding a distance from an optical center (prism=0) based of a prism quantity of the lens. Generally, the geometric center is infinitely equivalent to the optical center, the measuring point of a far viewing section can be therefore determined easily. However, after the prism thinning process, the geometric center is not equivalent to the optical center and the prism quantity is dislocated, so then a measuring point of far viewing section can not be determined.
The dislocation of the prism after a prism thinning process is generally determined according to an additive diopter, but the additive diopter is not still found when measuring a far viewing section. And it is necessary to adjust the dislocation of the prism in a right and a left lenses so that each sight through a right and a left lenses may become same. Accordingly, the dislocation of the prism can not be determined with only the additive diopter.
There may be further a case where the prism thinning process is not applied as an instruction by user and the lensmaker. Therefore, a measuring position of a far viewing section in a progressive focus lens, applied with the prism thinning process, can not be determined on the basis of only the prism quantity in a longitudinal direction of the lens.
Additionally, in a case of a progressive focus lens having a low power, there is a problem of incapable of measuring an additive diopter stability.
SUMMARY OF THE INVENTION
The present invention has been made in view of the foregoing problems and it is therefore a first object of the present invention to provide a lens meter capable of obtaining highly reliable measured data including the additive diopter of a progressive focus lens, even if applied with a special process such as prism thinning process.
A second object of the present invention is to provide a lens meter capable of obtaining highly reliable measured data including the additive diopter of a lens, even if the lens is a progressive focus lens with low power, and without necessity to depend on operator's experience.
Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, 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.
To achieve the objects and in accordance with the purpose of the invention, as embodied and broadly described herein, a lens meter of this invention, for determining the optical characteristics of a lens on the basis of the locus of measuring light projected on the lens, transmitted through the lens and detected by a photo-detecting device, comprises a display means for displaying the relation to adjust the lens to the optical axis of the measuring optical system, measuring mode selector means for selecting a measuring mode from a single focus lens measuring mode to a progressive focus lens measuring mode, a control means for measuring the lens at position measuring points distributed at predetermined intervals on the lens successively on a measuring optical axis and measuring the refractive power of the lens at each measuring point, an calculating means for calculating, based on the refractive power of the progressive focus lens at each measured position, a dislocation between a vertical standard line, on which a measuring position of the refractive power of the far viewing section, crossing a horizontal standard line on a progressive focus lens and passing through a geometrical center thereof and a measuring optical axis of the measuring optical system, and a movement conducting mark displayed on the display means to conduct the measuring to the vertical standard line direction based on the data obtained through the calculating means.
In another aspect of the present invention, a lens meter comprises a measuring optical system through which the measuring light to measure the optical characteristics of the lens passes, an optical measurement position detecting means for detecting the measuring light passed through the the lens, an optical characteristics calculating means for finding the optical characteristics of the lens based on a detected signal obtained from the optical measurement position detecting means, a display means for displaying the optical characteristics information of the lens found by the optical characteristics calculating means, a mode selector means for selecting a measurement mode between single focus lens measurement mode and a progressive multifocal lens measurement mode, a low power lens judging means for judging, when the progressive multifocal lens measuring mode is selected and thereby the far viewing section measuring step starts, whether the lens is a low power lens based on the optical characteristics value found by the optical characteristics calculating mode, a first determining means for determining, if judged the lens is not low power lens by the low power lens judging means, the far viewing section based on a variation in additive diopter per unit movement distance in a vertical standard direction, and a second determining means for determining, if judged the lens is low power lens by the low power lens judging means, the far viewing section based on a variation in additive diopter per unit prism variation in the vertical standard direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate an embodiment of the invention and, together with the description, serve to explain the objects, advantages and principles of the invention.
In the drawings,
FIG. 1 is a front view of a lens meter in a preferred embodiment according to the present invention;
FIG. 2 is a diagrammatic view of a measuring optical system included in the lens meter of FIG. 1;
FIG. 3 is a front view of a target plate shown in FIG. 2, showing the shape of a slit formed in the target plate;
FIG. 4 is a view of a slit image formed on a photo-detecting device;
FIG. 5 is a block diagram of controlling the lens meter of FIG. 1;
FIG. 6(a) through FIG. 6(e) are picture views showing respectively a picture displayed on a display 1;
FIG. 7(a) through FIG. 7(g) are another picture views showing respectively a picture displayed on a display 1;
FIG. 8(a) and FIG. 8(b) are another picture views showing respectively a picture displayed on a display 1;
FIG. 9(a) through FIG. 9(f) are flow charts explaining a series of steps of an additive diopter measuring procedure;
FIG. 10 is a plan view of a position detecting system included in the lens meter of FIG. 1;
FIG. 11 is a sectional view taken on line 11--11 in FIG. 10;
FIG. 12 is a plan view of showing each indicating position of a lens mark and others;
FIG. 13(a) and FIG. 13(b) are schematic sectional views of explaining prism thinning process respectively to a plus-lens and a minus-lens.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(General Construction)
Referring to FIG. 1 showing a lens meter in a preferred embodiment according to the present invention, a display 1 displays a reticle indicating the optical axis of a measuring optical system, a positioning cross target and measured results when the lens meter is set for a measuring mode. In FIG. 1, an indicating mark in an additive diopter measuring mode, which will be described later, is displayed on the display 1. The lens meter is provided with a print button 2, which is pushed to print out measured data, lens selector buttons 3a and 3b, a read button 4, which is pushed to read measured data, a progressive focus lens measuring mode selector button 5, a lens holder 6, a nose piece 7 for supporting a lens L, a positioning plate 8 for determining a longitudinal position of the lens L.
(Refractive Power Measuring System)
A refractive power measuring system included in the lens meter will be described hereinafter.
Referring to FIG. 2, four light emitting diodes (LEDs) 11' (11a, 11b, 11c and 11d) are disposed in a plane perpendicular to the optical axis of the refractive power measuring system and including the focal point of an objective lens 12. When the lens L is set on the nose piece 7, a microcomputer controls a LED driver to turn on the four LEDs 11a, 11b, 11c and 11d sequentially. The four LEDs 11a-11d are sequentially turned on by the LED driver repeatedly at predetermined intervals while the lens L is setting on the nose piece 7.
A measuring target plate 13 is provided with a crossing slits and disposed fixedly near the respective focal points of the objective lens 12 and a collimator lens 14. The four target images are blurred and dislocated by a distance proportional to the refractive power of the lens L, causing errors in the measurement. Accordingly, it is desirable to shift the target plate 13 to diminish the dislocation of the target images.
The nose piece 7 is disposed near the respective focal points of the collimator lens 14 and a focusing lens 15. Shown also in FIG. 2 are a half prism 16, and two linear image sensors 17 each comprising a plurality of photodiodes arranged in a linear array, and disposed perpendicularly to each other and to the optical axis.
Light emitted by the LED 11' is refracted by the objective lens 12, collimated by the collimator lens 14, refracted by the lens L and focused by the focusing lens 15 on the two image sensors 17. Thus, the image of the crossing slits of the target plate 13 as shown in FIG. 4 are formed on the image sensors 17.
A relation between the refractive power of the lens L and a focusing position of a measuring target image will be briefly described.
The four LEDs 11' (11a-11d) are turned on individually to illuminate the target plate 13. If the lens L is not set on the nose piece 7, images of the crossing slits of the target plate 13 (hereinafter referred to as "target images") formed on the image sensors 17 by the light emitted by the LEDs 11a, 11b, 11c and 11d overlap each other.
If the lens L has only spherical refractive power, the target image is shifted on the imaging device by a distance corresponding to the spherical refractive power; the target image formed by the light emitted by the LED 11a or 11c is shifted along the line linking LED 11a to LED 11c, and the target image formed by the light emitted by the LED 11b or 11d is shifted along the line linking LED 11b to LED 11d.
If the lens L has only cylindrical refractive power, the lens L refracts the incident light in a direction perpendicular to the principal meridian (or parallel to the principal meridian). The cylindrical refractive power of the lens L can be calculated on the basis of the distance of shifting of the target image.
If the lens L has both spherical refractive power and cylindrical refractive power, the target image is shifted on the image sensors 17 by distances according to the spherical refractive power and cylindrical refractive power of the lens L.
Suppose that the respective coordinates of the respective centers of the target images formed respectively by the light emitted by the LEDs 11a, 11b, 11c and 11d are A(x a , y a ), B(x b , y b ), C(x c , y c ) and D(x d , y d ). Then, ##EQU1## where S is the spherical refractive power, C is the cylindrical refractive power, θ is the axial angle and PQ is the prism quantity.
A microcomputer 25 calculates the spherical refractive power, the cylindrical refractive power, the axial angle and the prism quantity of the lens L by using the coordinates of the target images formed by the light emitted by the LEDs 11a, 11b, 11c and 11d, and the expressions (1) to (8). If shifting the target plate 13, the above data will be corrected with the shifting distance.
(Control Circuit)
Referring to FIG. 5, signals provided by the two image sensors 17 are transferred through a CCD driving circuit 21 to a comparator 22 and a peak hold circuit 23. A peak voltage detected by the peak hold circuit 23 is converted into a corresponding digital peak signal by an A/D converter 24, and the digital peak signal is given to the microcomputer 25, the digital peak signal corresponding to the peak voltage detected by the peak hold circuit 23 is transferred through the microcomputer 25 to a D/A converter 26, the D/A converter 26 converts the digital peak signal into a half voltage signal corresponding to half the peak voltage, and then the half voltage signal is given to the comparator 22. The comparator 22 compares the half voltage signal with a signal given directly thereto by the CCD driving circuit 21 and provides a strobe signal. When the strobe signal is provided by the comparator 22, a signal provided by a counter 27 is given to a latch 28. The position of a shading edge is determined from the waveform, the microcomputer 25 determines the coordinates, and then the microcomputer 25 calculates the optical characteristics of the lens L on the basis of the coordinates.
The microcomputer 25 processes the position data, and then a display control circuit 29 controls the display 1 to display the processed position data together with data stored in the memory in characters and graphs.
(Operation)
Operation of the lens meter in a measuring mode for measuring the optical characteristics of a single-focus lens will be described.
When measuring the spherical refractive power, cylindrical refractive power and axial angle of a lens, a reticle is displayed on the CRT display 1, of which a center point is positioned on an optical axis of the refractive power measuring system. The LEDs 11a-d of the measuring optical system are turned on at predetermined intervals and the lens is mounted on the nose piece 7. Then, the refractive power on the measuring optical axis is calculated and displayed on the CRT display 1. The dislocation of the lens is calculated on the basis of the prism quantity (Formula of Plentis). In a display control circuit 29, the target image is superposed on the reticle on the CRT display 1 at a position corresponding to the dislocation. Measured data obtained when the reticle and the target image meet a predetermined positional relation represents the optical characteristics of the lens.
The operation of the lens meter in a measuring mode for measuring the optical characteristics of framed progressive multifocal lens will be described hereinafter.
The progressive focus lens measuring mode selector button 5 is depressed to select a measuring mode for measuring the optical characteristics of framed progressive multifocal lens. Before a lens is put on the nose piece 7, as shown in FIG. 6(a), two curves 30 and a longitudinal rectangular target 31 indicating a measuring point are displayed on the display 1. The two curves 30 imitate a progressive section or band, and are displayed fixedly on the display 1.
Either the right lens selector button 3a or the left lens selector button 3b is depressed to specify a lens to be tested. A selected lens is put on the nose piece 7, and then the positioning plate 8 is brought into contact with the lower end of the lens. The lower or upper ends of the lens means that in a longitudinal direction of the lens of when person puts on his spectacles.
The position of the lens is adjusted so that a section of the lens which is supposedly the far viewing section of the framed lens, a little to the upper end of the lens, is positioned on the nose piece 7 to start a far viewing section measuring step. Referring to FIG. 6(b), a marker 32, flashing on and off at a lower position on the display 1, indicates a mark to move the target 31. And an operator can find the movement distance and direction of the lens based on a position of the target 31 to the marker 32. The far viewing section of the progressive multifocal lens is positioned on the standard longitudinal axis mentioned above, the marker 32 indicates the position of the standard longitudinal axis accordingly.
Based on the measured data representing the refractive power of the far viewing section, it is judged whether the far viewing section is low power lens. Namely, the refractive power data (S, C, A) is first factorized into each component of X-Y coordinate described hereinafter. If the X or Y component, where the X component is S+Csin 2 θ and the Y component is S+Ccos 2 θ, is less than a predetermined reference value, particularly 0.75 D in the present embodiment, the lens is judged to be a low power lens.
Case (A) of the lens being not low power lens.
If judged that the lens is not a low power lens, the target 31 is displayed at a position determined according to the following.
If the lens is a spherical lens, a direction and distance from the standard longitudinal axis is found on the basis of the prism value in a lateral direction at each measuring point. Accordingly, the target 31 is displayed at a position indicating a relative position of each measuring point to the marker 32.
If the lens is an astigmatic lens, the prism value of the lens in a lateral direction is 0 on the astigmatic axis. By offsetting influence caused by the astigmatic lens, the prism value at each measuring point is corrected into data representing a distance and direction from the standard longitudinal axis. The above method may be utilized for processing all progressive focus lens because spherical lens is considered to be a special astigmatic lens representing C=0.
In one astigmatic lens including each value of S, C, A, the prism quantity (P x , P y ) at A point (x, y) on X-Y coordinate is as follows, putting the optical center of the lens at "0", the standard longitudinal axis in Y-axis:
P.sup.x =-(D.sup.xx ·x+D.sup.xy ·y) (1)
P.sup.y =-(D.sup.yx ·x+D.sup.yy ·y) (2)
and the prism quantity (P xo , P yo ) at B point (0, y) is as follows:
P.sup.xo =-D.sup.xy ·y (3)
P.sup.yo =-D.sup.yy ·y (4)
provided that
D xx =S+Csin 2 θ,
D yx =-Csin θ ·cos θ (=D xy ),
D yy =S+Ccos 2 θ,
where C read as minus.
Based on the above formula, the following formula is obtained
P.sup.xo =D.sup.xy ·(P.sup.y ·D.sup.xx -P.sup.x ·D.sup.yx)/(D.sup.xx ·D.sup.yy -D.sup.yx ·D.sup.xy)
and a position at x=0 and a target displaying position are respectively determined by offsetting P xo from P x .
The offset calculation is also utilized to observe a position of the lens described hereinafter.
The lens is moved by the operator so that the target 31 may be superposed on the marker 32 as shown in FIG. 6(c), data "a" representing the refractive power at the position are stored in the memory.
When superposed on the marker 32, the target 31 is replaced with a lateral rectangular target 33, and the target 33 is displayed above the marker 32 on the display 1, referring to FIG. 6(d) . Then the lens is moved so that the target 33 indicating a measuring point may be superposed on the marker 32 as shown in FIG. 6(e). The target 33 is controlled so as to be superposed on the marker 32 when the lens is moved by a calculated distance based on the prism value in a longitudinal direction of the lens. The data "b" representing the refractive power at a position, where the target 33 agreed with the marker 32, is stored in the memory.
By comparing respective spherical refractive power between the data "a" and "b" representing the refractive power stored in the memory, it is judged whether the present measuring point is on a progressive focus section or on near the far viewing section outside the progressive focus section. Namely, if a difference between the data "a" and "b" is within a predetermined value (equal to approximately 0), it is judged that the measuring point is near the far viewing section. If the difference is not within the predetermined value to the contrary, it is judged that the measuring point is (or may be) in the progressive focus section.
(A-1) A case judged that the measuring point is near the far viewing section of the lens which is not low power lens will be explained as follows.
In the case that the measuring point is near the far viewing section, the marker 32, showing only the moving direction of the target 33, is displayed above the target 33 as shown in FIG. 7(a). The lens is moved by the operator, toward the operator in FIG. 7, so that the target 33 is moved toward the marker 32 on the display 1. The refractive power of the lens is measured sequentially during moving the lens, and the microcomputer 25 converts the prism quantity into the movement distance of the lens and detects variations in additive diopter per unit movement distance.
On detecting that a measuring position is shifted to the progressive focus section, based on the variation in additive diopter per unit movement distance, the target 33 is replaced with a circular target 34, then the marker 32 is displayed below the target 34, referring to FIG. 7(b). The progressive focus section may be detected where a spherical refractive power value is larger by a regular value (for instance 0.12 D) than the spherical refractive power of the data "b" representing the refractive power.
A distance from the start position of additive diopter varies according to a kind and an additive diopter of progressive focus lens. Commonly, in progressive focus lens on the market, an upper part by about 4-8 mm from the start position of additive diopter corresponds to the far viewing section designated by each lensmaker. When a movement distance of the lens is calculated based on the measured prism quantity in a longitudinal direction of the lens, and based on the data, the lens is moved by a predetermined distance, 6 mm in the present embodiment; the target 34 is displayed superposed on the marker 32.
In this embodiment, noting that the far viewing section is provided with a wide area, the lens is moved by a regular distance from the measuring point detected on the progressive focus section to simplify the operation. It is also possible to move the lens on the basis of a position where a spherical refractive power is larger by a regular quantity than the refractive power "b".
On receiving a signal that the lens is moved by a predetermined distance, referring to FIG. 7(c), the marker 32 is converted to a cross marker 35 by which an agreement of the target 34 with the marker 32 is recognized. A stable measured data at the measuring point in the far viewing section is detected and stored in the microcomputer 25.
After stored the measured data in the far viewing section in the microcomputer 25, a near viewing section measuring step starts automatically, referring to FIG. 7(d) . Such automatic shift of measuring mode from the far viewing section measuring step to the near viewing section measuring step prevent dislocation of lens caused by shift with a selector button. The near viewing section measuring step starts from moving a target 36 to the upper side on the display 1, namely by moving a measuring point to the lower side on the lens. The target 36 is moved on the basis of a movement distance reduced from the prism quantity in a longitudinal direction of the lens, imaging that a measuring point moves in the progressive focus section.
In a case of reducing a variation in the prism quantity to a movement distance, measuring error is often caused at a small refractive power. Therefore, when a refractive power is less than a predetermined reference value, for example less than 0.5 D, the movement distance is determined on the basis of the increase of additive diopter. The same process can be also applied for a lens of which prism variation is disordered.
The additive diopter is measured sequentially while the target 36 moving in the progressive focus section, and the measured data is displayed on an indicator 37, and also on a bar graph 38. These indications on the indicator 37 and the bar graph 38 enable the operator to find a rough additive diopter and the variation, even before the near viewing measuring step is completed.
A difference between a cylindrical refractive power at a measuring point and the same at a far viewing section is detected, and converted to a numerical value to be displayed on an indicator 39 as optical distortion quantity. Based on the numerical value displayed on the indicator 39, it is monitored whether the measuring point exceeds a predetermined reference value, for example 0.25 D, from the progressive focus section. If exceeded the predetermined reference value, the measured value is cancelled, and the direction and the dislocation quantity of the measuring position are found from a prism value in a lateral direction of the lens simultaneously. Then the target 36 is displayed at a position outside the progressive focus section as shown in FIGS. 7(e) and 7(f).
Measuring errors in a lens of which the refractive power is lower will be corrected on the basis of variations in optical distortion quantity with a movement of the lens by the operator, namely of whether the optical strain quantity increases according to the movement of the lens. The movement distance of the lens is determined based on data including variations in prism quantity. The same process can be also applied for a lens of which prism variation is disordered.
As mentioned above, the additive diopter is measured through the near viewing section to lower end of the framed lens. And when the target 36 is positioned at approximately center between two curves 30 as shown in FIG. 7(g), the near viewing section measuring step is completed.
The variation in additive diopter near the near viewing section become slow, not constant.
Then a measured value at a position where a variation in additive diopter per unit movement distance is lower than a regular reference value and within a predetermined distance from the far viewing section (within about 18-25 mm distance from the far viewing section, lens makers indicate commonly a distance from an eyepoint, and the distance may be from a progressing start point), is rounded off to 0.25 D unit (=present unit refractive power of progressive focus lens), and estimated to be an additive diopter of the near viewing section. The regular reference value may be indicated with an absolute value, and more precise with the proportion of variation to the maximum variation of the additive diopter. The near viewing section measuring step is completed on finding the estimated refractive power of the near viewing section and the measured data within a predetermined diopter, ±0.05 D in the first embodiment. Therefore, the additive diopter of the near viewing section can be automatically found.
(A-2) In the case that the measuring point is in the progressive focus section, the target 33 is displayed above the marker 32 as shown in FIG. 8(a). The lens is moved so that the target 33 is moved toward the marker 32 on the display 1. The refractive power of the lens is measured sequentially daring moving the lens, and the microcomputer 25 converts the prism quantity into movement distance and detects a variation in additive diopter per unit movement distance.
When a measuring position where the additive diopter variation is less than a predetermined reference value, 0.03 D/mm in this embodiment, is judged to be outside progressive focus section, and the measuring point is, after moved by about 2 mm from the measured position, detected to be in the far viewing section, the marker 32 is changed to a cross marker 35, referring to FIG. 8(b). A stable measured data at the measuring point in the far viewing section is detected by and stored in the microcomputer 25. And then a near viewing section measuring step starts automatically, same as the above (A-1).
A case (B) in which the measuring point is judged to be near the far viewing section of the low power lens will be explained as follows. The basic measuring step in this case is the same as in the non-low power lens of a case (A) mentioned above, so the difference in the process will be described selectively.
A position at x=0 and a display position of the target are detected by offsetting p xo from P x in a similar way to the above (A) process. In a low power lens, a measuring precision of a refractive power of far viewing section is hardly affected by a slight dislocation from the standard longitudinal axis, but may easily be seriously influenced by errors of processing precision on manufacture. Therefore, differently from the (A) process, if S+Csin 2 θ as the X component is less than 0.75 D, the moving sensitivity of the target is lowered.
Instead of the method for lowering the moving sensitivity of a target, it is also able to utilize a position where the prism value is near "0" and become the minimum based on variation in cylindrical value, as that on the standard longitudinal axis.
Then, if S+Ccos 2 θ exceeds 0.75 D, the next step returns to (A) step to repeat the additive diopter measuring procedure, conversely if S+Ccos 2 θ is less than 0.75 D, the next step is as follows.
The lens is moved by the operator so as to adjust the target 31 to the marker 32, referring to FIG. 6(c). Then data "a" representing a refractive power and prism quantity Pa at the position where the target 31 is superposed on the marker 32 on the display 1 are stored in a memory. At agreement with the marker 32, the target 31 is replaced with a lateral rectangular target 33 displayed below the marker 32 as shown in FIG. 7(a). Thereby, the measuring point is shifted to lower side of the lens to search a point where an additive diopter exceeds a refractive power "a" by a predetermined degree. When the point is detected, a difference between a measured prism quantity Pb at the measured point and the prism quantity Pa is found to determine a unit quantity of variation in prism.
Next, the target 33 is displayed above the marker 32. The lens is moved so that the target 33 is moved toward the marker 32 to shift the measuring point to the upper side of the lens. Sequence measurement is taken during the lens moving, based on measured data, a variation in refractive power of the lens compared with a variation in prism quantity is calculated, and then a variation in additive diopter per unit prism variation quantity is found.
In low power lens, the additive diopter per unit prism variation quantity is regarded as an index to determine the far viewing section, because the low power lens will be seriously affected by errors in measurement, it is therefore not useful to measure a variation in additive diopter per unit movement quantity as same as (A) step.
Incidentally, a prism variation is little at a slight variation in refractive power, therefore, a measuring point may not reach to the far viewing section in the method for dividing the steps and judging whether it is far viewing section. An additive diopter near the starting point of additive diopter, on the lens design, increases gradually at the rate of increase, not at a linear function rate.
On the distinguishing characteristic of variations in additive diopter, it is judged whether the measured position is sufficiently near the additive diopter starting point, based on a variation in additive diopter per unit prism variation. The additive diopter remains slightly at the measured position, and the refractive power step of progressive focus lens is predetermined at 0.25 D step as mentioned above. The refractive power of far viewing section of the lens may be estimated to be a value rounded off by 0.25 D unit to a minus direction from a refractive degree at the measured position accordingly; if the refractive power diopter is +0.35 D, the additive diopter of the far viewing section is estimated at +0.25 D.
If an estimated value of the refractive power of the far viewing section is found, the measuring point is further shifted toward the far viewing section. When the measuring point is at a position where a value difference between each refractive power at each measuring point and the estimated value become within a predetermined reference value (±0.06 D in the present embodiment), the marker 32 is changed to a cross marker 35, as shown in FIG. 7(c), to indicate that the measured position is in the far viewing section. Then, the refractive power of the far viewing section is stored in a memory.
Subsequently, the measurement step in the far viewing section is automatically converted into the near viewing section measurement step. The measurement operation in the near viewing section is almost similar to that in (A) step, but if the y-component of the measured refractive power is less than 0.75 D, the movement distance of the target is determined by an increased quantity in additive diopter.
The above method for finding the far viewing section in the low power lens may be utilized in a general lens, also in a special lens of which refractive power in the far viewing section is irregular.
The above described measuring operation is also shown in FIG. 9(a) through FIG. 9(f) showing flow charts explaining a series of steps of an additive diopter measuring procedure.
The second embodiment of the present invention will be described hereinafter, referring to FIGS. 10 and 11. In the second embodiment, compared with the first embodiment, a position detecting system for positioning the lens and detecting the position of the lens is further provided with a lens meter, and the display position of the target 33 is determined based on data detected through the lens position detecting system. The refractive power measuring system, similar to the first embodiment, is omitted in this embodiment.
Referring to FIGS. 10 and 11, a rack 42 is supported in a horizontal position within a positioning plate 8 for lateral movement and a guide pin 41 is fixed to the rack 42. The positioning plate 8 is for supporting a framed lens, particularly only a lens in FIG. 10. The guide pin 41 is biased toward the left, as viewed in FIG. 11, by coil springs 43. The positioning plate 8 is fixed to a rack 42 supported for longitudinal movement and biased continuously toward the front by a spring 45. A pinion 47 fixedly mounted on one end of a rotating shaft 46 engages the rack 44 and is moved longitudinally together with the rack 42 by the rack 44. A gear 48 is mounted fixedly on the other end of the rotating shaft 46. The revolution of the gear 48 is detected by a potentiometer 49 to detect the distance of lateral movement of the guide pin 41. The revolution of a pinion 50 engaging the rack 44 is detected by a potentiometer 51 to detect the distance of longitudinal movement of the positioning plate 8. The lens L is held in contact with the positioning plate 8 and the guide pin 41, so that the distance of longitudinal movement and that of lateral movement of the lens L can be detected through the detection of the revolution of the gear 48 and that of the pinion 50. Based on the detected data, each display position of the target and marker is determined.
In the first embodiment, a display position of the target is determined by reducing a variation in prism quantity into a movement distance of the lens (the measuring point), or by utilizing a variation in additive diopter per unit prism variation, instead of that per unit movement distance, to avoid the influence by errors in measurement. On the other hand, in the second embodiment, the movement distance of the lens can be directly detected, so that the detected data may be utilized for determining a display position of the target.
Compared with the first embodiment, the movement distance of the lens can be more precisely detected by employing the apparatus of the second embodiment. It is therefore possible to judge accurately a dislocation direction of the measuring point when the measuring point is outside the progressive focus section, and also to move the target according to the movement distance of the lens, particularly useful to measure a cylindrical lens. It is also possible to find the additive diopter accurately since a position of the near viewing section may be precisely determined by displaying a distance from the far viewing section.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For instance, it is possible to display only a relation between a target and a marker on a display without two curves imitating a progressive focus section (band), and to move a progressive focus section (band) toward a target.
Each step in the above embodiments may be partially omitted to simplify the operation. For instance, in a measuring mode of a refractive power of far viewing section, an operation to find a starting position of additive diopter may be omitted for an operator who can measure the far viewing section if found a position of a standard longitudinal axis of a lens. If unnecessary to see variations in additive diopter of the progressive focus section on sifting to a measurement of the near viewing section, it is possible to move the lens directly toward near the viewing section.
The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents.
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A lens meter projects measuring light onto a lens, detects the measuring light traveled through the lens at a light detecting element, and determines the optical characteristics of the lens on the basis of the detected data obtained from the light detecting element. The lens meter provides a display device for displaying the relation to adjust the lens to the optical axis of the measuring optical path, measuring mode selector device for selecting a measuring mode from a single focus lens measuring mode to a progressive focus lens measuring mode, a control device for measuring the lens at position measuring points distributed at predetermined intervals on the lens successively on a measuring optical axis and measuring the refractive power of the lens at each measuring point. A dislocation between a vertical standard line, on which a measuring position of the refractive power of the far viewing section, crossing a horizontal standard line on a progressive focus lens and passing through a geometrical center thereof is calculated based on the refractive power of the progressive focus lens at each measured position, and a measuring optical axis of the measuring optical path, and a movement conducting mark is displayed on the display device to conduct the measuring to the vertical standard line direction based on the calculated data.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for reliably monitoring the speed of a movable coordinate measuring device, and relates to a coordinate measuring appliance with such a coordinate measuring device, in particular a probe. The coordinate measuring device can be moved linearly, for example in a plurality of directions.
Such coordinate measuring appliances are generally known, for example from US 2001/013177 A1. However, the invention is not restricted to a specific type of coordinate measuring devices (for example a scanning probe of the switching or nonswitching type).
When the coordinates of measured objects are measured with movable coordinate measuring devices, it is necessary to take specific precautionary measures. On the one hand, the measured object itself has to be protected against mechanical damage which could occur when the coordinate measuring device impacts against the measured object. On the other hand, persons and parts of the measuring arrangement themselves also have to be protected against such mechanical injury or damage. The speed of the coordinate measuring device therefore has to be reliably monitored, i.e. monitored in a way which is particularly reliable with respect to faults.
Monitoring is understood in particular to be a process which goes beyond the detection of the speed and use of this information for the normal operation of the coordinate measuring appliance. In this sense, detecting the speed (for example by evaluating the tachosignal) and using the information about the detected speed (for example by comparing it with a speed setpoint value) merely to adjust the speed or to control it therefore does not constitute monitoring. Instead, monitoring is understood to mean that the detection of the speed and/or the normal operation of the coordinate measuring appliance are/is monitored. The normal operation of the coordinate measuring appliance comprises, in particular, only that part of the operating process which is necessary to determine the coordinates but not that part of the operating process which ensures operation in the sense described in the introduction to the description. Monitoring is also understood in particular to mean that the detected speeds lead to a safety measure which goes beyond the normal operation of the coordinate measuring appliance. The safety measure is, for example, the generation of a fault signal and/or a warning signal.
DE 199 37 737 A1 describes a device and a method for reliably monitoring the rotational movement of a shaft. In the introduction to the description of the document, what is referred to as a resolver is mentioned as a rotational movement sensor. The resolver is a rotational transformer whose rotor is connected to the shaft to be monitored and whose stator has two windings which are separate from one another and which are arranged offset with respect to one another by a rotational angle of 90° on the outer circumference of the shaft. The two stator windings receive, by means of the transformatory coupling, a signal which is fed via the rotor winding. The signals at the output of the stator windings represent a first signal and a second signal, which respectively represent the time profile of the rotational angle position of a first reference point and of a second reference point of the shaft.
DE 199 37 737 A1 proposes that evaluation means contain a comparator with which instantaneous values of the first and second signals can be compared with one another on the basis of a predefined geometric relationship. Only the angular speed or the absolute speed at the circumference of the shaft is monitored directly with this comparator.
In the introduction to the description of the document, it is also mentioned that, in addition to the resolver, at least one further rotational movement sensor is arranged in the region of the shaft. However, this is necessary only because in the corresponding arrangements the evaluation circuits are not suitable for ensuring reliable monitoring of rotational movements on the basis of the resolver signals. It would even be possible to use two mutually separate rotational movement sensors, for example incremental signal transmitters, for reliable monitoring. Said signal transmitters are generally used solely for reliably monitoring the rotational movement of the shaft. In contrast, the resolver could be used to control the rotational movement of the shaft in the normal operating mode.
The costs and the technical expenditure which are incurred for additional movement sensors are high. In particular, the movement sensors and the evaluation device which is combined therewith have to function reliably and precisely in any conceivable operating situation.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to specify a coordinate measuring appliance and a method for reliably monitoring the speed of a coordinate measuring system which make it possible to reduce the costs and the technical expenditure which are incurred in monitoring.
It is proposed to calculate and/or determine the speed of the coordinate measuring device in each case from two different signal sources which are independent of one another, with the two signal sources also being used for the operation of the coordinate measuring appliance. A first value of the speed is calculated, in particular, from measured values of the coordinate measuring system. For this purpose, the measured values have information about positions of the coordinate measuring device. This information is used to calculate the speed of the coordinate measuring device, for example by derivation of the position over time.
A second value of the speed is determined, in particular, from measurement signals of an additional movement sensor (additional to the coordinate measuring system). The measurement signals of the additional movement sensor are also used for controlling a drive device of the coordinate measuring device. For example, as described in DE 199 37 737 A1, it is possible to use a resolver or a rotational transformer with just one signal generator as an additional movement sensor.
In particular, a method for reliably monitoring the speed of a movable coordinate measuring device is proposed in which the coordinate measuring device is part of a coordinate measuring system for determining coordinates of measured objects. Furthermore,
(a) a first value of the speed is calculated from measured values of the coordinate measuring system, wherein the measured values have information about positions of the coordinate measuring device and wherein the measured values are also used to determine the coordinates, (b) a second value of the speed is determined from measurement signals of at least one additional movement sensor, wherein the measurement signals are also used, or can be used, for controlling a drive device of the coordinate measuring device, and (c) a fault signal is generated if, according to a predefined criterion, the first value and/or the second value differ from one another, from a setpoint value and/or from a limiting value.
A coordinate measuring device is understood, in particular, to be all the movable parts of the coordinate measuring system which are moved for the purpose of determining the coordinates of the measured object or measured objects. In a coordinate measuring appliance of the gantry design, these include, in particular, the actual probe but also the parts which are moved along with the probe, specifically for example the bridge of the gantry, a carriage which can move in relation to the bridge and the parts which can move, together with the probe, in relation to the carriage. For this reason, the various parts of the coordinate measuring device can be at different speeds. It is therefore correspondingly possible to monitor different speeds or merely individual parts of the coordinate measuring device in terms of their speed. Alternatively or additionally it is possible, for example, to monitor different speed components of the speed of a part or of the entire device.
A fault signal is understood, in particular, to be a signal which is generated automatically when the predefined criterion is met, i.e. when the fault occurs. The meaning and/or cause of the fault may vary in nature here. For example, a fault may be present in the additional movement sensor and/or during the processing of the measurement signals supplied by the movement sensor. In particular, an integrated circuit may have failed. However, it could also be a software fault which, for example in certain operating situations, supplies incorrect results for the first or second values of the speed. The fault signal may, for example, be displayed and/or automatically trigger intervention into the operation of the coordinate measuring appliance. For example, the fault signal can therefore be a switch-off signal. In order to protect equipment and/or persons it is generally necessary to stop all the drives of the coordinate measuring device even if only one of the speed values determined in different ways indicates the presence of a fault.
In particular, the first value and the second value can each be updated repeatedly, and the predefined criterion can be repeatedly applied to the updated values in each case.
The predefined criterion can also vary in nature. If, for example, the two values differ from one another by more than a predefined limiting value at a certain point in time or over a defined time period, the fault signal can be generated. In this case it is to be assumed that one of the two partial procedures (either for determining the first value of the speed or for determining the second value of the speed) is faulty.
Alternatively or additionally it is possible to predefine a maximum value of the maximum acceptable speed. For example, the maximum value is changed in the course of time, in particular as a function of the operating state, of signals/states of protection devices such as, for example, photoelectric barriers and/or step mats, of a predefined setpoint value and/or of the local region in which the coordinate measuring device is located. In this context it may be permitted that when the maximum value is reduced, the old, relatively high maximum value still applies for a transition time, said maximum value being required for braking the coordinate measuring device owing to inertia. A fault occurs in particular even if only one of the determined speed values reaches or exceeds the maximum value.
The fault signal is preferably generated if one of the speed values continuously reaches and/or exceeds the maximum value over a time interval of predefined length. Alternatively or additionally it is possible, when determining whether the maximum value is reached and/or exceeded, to use in each case a smoothed speed value which is obtained by smoothing fluctuations over time in the initially determined or calculated value. In both cases it is possible as a result of this to ensure that a very brief upward transgression (caused in particular by a temporary measuring fault) or the very brief attainment of the maximum value still do not have any effects on the operation of the coordinate measuring appliance.
In addition, the criterion can also include a setpoint value of the speed which is predefined, for example, by a control program. If the first value of the speed or the second value of the speed are significantly above the setpoint value, the presence of a fault should also be concluded. Given fault-free operation, the additional movement sensor of the drive device serves, in particular, to adjust the actual speed to the setpoint value.
All the statements in this description relating to “the speed” and/or method features can each apply separately to individual speed components (for example in the x, y and z directions of a Cartesian coordinate system). In particular, the reliable monitoring of the speed can in each case be carried out separately and independently for the various drive devices of a coordinate measuring system or movement components (for example in the x, y and z directions of the coordinate system), with each of the drive devices controlling the movement of the coordinate measuring device along one of a plurality of independent coordinate axes.
A plurality of electric motors which together bring about the total movement of the coordinate measuring device are preferably provided. In this context, the movements of the electric motors are clearly assigned to movement components of the movement of the coordinate measuring device. For example, in each case at least one electric motor is provided for a linear movement of the coordinate measuring device, and each of the linear movements here can occur exclusively in one of three directions which are arranged perpendicular to one another in pairs. As a result, it is therefore possible to move to any desired point on a direct path within an achievable range of movement. In particular, the three speed components of the three linear movements can be monitored. This includes the case in which more than one electric motor is used to generate at least one of the movement components (for example one of the three linear movements). In this case, the speed of the electric motors can be monitored independently of one another for the same movement component or monitored jointly (for example by forming a mean value of the speeds), or just one of the electric motors is monitored.
The clear assignment of the electric motors to the movement components also includes the case in which the movements which are generated by the individual electric motors are coupled kinematically. In this case, the second value of the speed can be determined from measurement signals of a plurality of the additional movement sensors. For example, the movements of a first electric motor and of a second electric motor are coupled kinematically in such a way that the movement of the first electric motor contributes to the combined movement multiplied only by a factor of less than one, while the movement of the second electric motor contributes one-to-one (or alternatively multiplied by a different factor) to the combined movement.
The determination of coordinates in a coordinate system is not restricted to Cartesian coordinates. Instead, coordinates of any type can be determined, for example polar coordinates, cylinder coordinates etc.
A coordinate measuring appliance is understood not only to be an appliance with which coordinates can be determined in a coordinate system but also an appliance with permits a position of a measured object to be checked. For example, the coordinate measuring device can have a mechanical sensor and/or an optical sensor.
An important advantage of the invention is that signals from the normal operating mode of the coordinate measuring appliance are used for reliable monitoring of the speed, for which, at least to a certain extent, a high-precision evaluation of these signals can also be used. The determination of the coordinates of measured objects in coordinate measuring appliances is therefore generally highly precise. It is therefore also possible to determine a precise speed value. In order to increase the precision when calculating the speed, the coordinate measuring appliance can have a high-precision time signal generator which supplies the time base for the derivation over time. Also, the sampling rate which is available with modern coordinate measuring appliances when recording the measured values for the determination of the coordinates is so high that the calculation of the speed can also be configured in a very precise way.
The scope of the present invention also includes a coordinate measuring appliance which has the following:
(a) a coordinate measuring system for determining coordinates of measured objects with a coordinate measuring device, in particular with a probe, which can be moved at least in one direction, driven by at least one drive device, (b) an evaluation device of the coordinate measuring system which is configured to determine the coordinates from measured values which have information about positions of the coordinate measuring device, (c) a drive control device with a movement sensor which generates measurement signals of a movement of the coordinate measuring device which are used by the drive control device to control the drive device of the coordinate measuring device, (d) a monitoring device for reliably monitoring the speed of the coordinate measuring device, (e) a first speed determining device of the monitoring device which is connected to the coordinate measuring system and is configured to calculate a first value of the speed from measured values of the coordinate measuring system, and (f) a second speed determining device of the monitoring device which is connected to the movement sensor and is configured to determine a second value of the speed from the measurement signals of the additional movement sensor.
The coordinate measuring appliance can also have a device for detecting an overcurrent, i.e. a current for supplying the drive device or a part of the drive device which is higher than an anticipated value or maximum value. If the detected current reaches or exceeds the anticipated value or the maximum value, suitable protective measures can also be taken (for example switching off of the drive or drives).
The monitoring device can also be an object or an arrangement which forms a unit which is separate from the coordinate measuring appliance. For example, an existing coordinate measuring appliance can be retrofitted with such a monitoring device.
In particular, the first speed determining device can have a first microcomputer, and the second speed determining device can have an additional, second microcomputer. In addition, the first speed determining device and the second speed determining device can each be connected to a switch-off device for switching off a power supply of the drive device. Using various microcomputers increases further the reliability of the monitoring. Not only are various measurement signals used for calculating the first and second values of the speed, but also the calculation of the speed values or determination of the speed values occurs in different components.
One of the two microcomputers, in particular the first microcomputer, can also serve to control the operation of the coordinate measuring appliance. In practice, this constitutes an embodiment which can be implemented at low additional cost because the control computer which is present in any case merely has to be programmed or configured in such a way that it also calculates the speed from the coordinates. In addition, all that is necessary is to provide an additional, second microcomputer or to configure correspondingly such a microcomputer which is already present, in order to calculate the second value of the speed from the signals generated by the movement sensor.
For further advantages and further possible refinements of the coordinate measuring appliance, reference is made to the description of the method according to the invention.
Exemplary embodiments of the invention will now be described with reference to the appended drawing. In the drawing:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows a coordinate measuring appliance of a gantry design,
FIG. 2 is a schematic view of an arrangement which has components for processing signals during the operation of a coordinate measuring appliance,
FIG. 3 is a schematic view of an arrangement with a power stage (output stage) from which an electric motor is supplied with motor current, and
FIG. 4 is a schematic view of an arrangement with a computer and at least one microcontroller.
DESCRIPTION OF THE INVENTION
The coordinate measuring appliance (CMA) 11 of a gantry design which is illustrated in FIG. 1 has a measuring table 1 , and columns 2 , 3 are arranged in such a way that they can move over said measuring table 1 in the Z direction of a Cartesian coordinate system. The columns 2 , 3 form, together with a crossmember 4 , a gantry of the CMA 11 . The crossmember 4 is connected at its opposite ends to the columns 2 and 3 . Electric motors (not illustrated in more detail) cause the columns 2 , 3 to move linearly in the Z direction. In this case, each of the two columns 2 , 3 is assigned an electric motor.
The crossmember 4 is combined with a transverse carriage 7 which is movable with air bearing along the crossmember 4 in the X direction of the Cartesian coordinate system. The instantaneous position of the transverse carriage 7 relative to the crossmember 4 can be detected on the basis of a scale division 6 . The movement of the crossmember 4 in the X direction is driven by a further electric motor.
A quill 8 which can move in the vertical direction is mounted on the transverse carriage 7 and is connected at its lower end to a coordinate measuring device 5 via a mounting device 10 . A probe 9 is detachably arranged on the coordinate measuring device 5 . The coordinate measuring device 5 can be moved relative to the transverse carriage 7 in the Y direction of the Cartesian coordinate system, driven by a further electric motor. As a result of the total of four electric motors, the probe 9 can therefore be moved to any point which is in the intermediate space defined by the columns 2 , 3 underneath the crossmember 4 and above the measuring table 1 .
FIG. 2 is a schematic view of a measuring device 22 which can be moved in order to acquire coordinates of a measured object by determining the position of the measuring device 22 (for example the position of a sensing element). In the present exemplary embodiment, the measuring device 22 can move with respect to three linear axes which are independent of one another. Each of the three linear axes has an incremental scale 24 . The determination of the position of the measuring device 22 with respect to such an incremental scale is known per se from the prior art (for example magnetic or photoelectric sensing). For example, the position can, as described in DE 43 03 162, be determined by using an incremental photoelectric measuring system. A measuring system which can also be used within the scope of the present invention to determine the coordinates or positions is described in WO 87/07944. An interference measuring principle can be applied.
The reference number 25 in FIG. 2 denotes a corresponding signal transmitter which, according to the current position of the measuring device 22 , uses the incremental scale 24 to generate a position signal which is further processed by a downstream interpolator 26 . The interpolator 26 also supplies values which are valid for positions between the marks of the incremental scale 24 and which can be utilized by a downstream coordinate determining device 28 .
The coordinates which are determined by the coordinate determining device 28 (and which are defined in particular in the coordinate system of the incremental scales 24 ) are fed to a first determining device 32 for the determination of the speed of the measuring device 22 . The speed is determined in each case by forming the derivation of the individual coordinates over time.
In addition, the first determining device 32 (and likewise a second determining device 34 described below) can be configured to detect, according to the predefined criterion, whether a fault is present or whether the criterion is met. In particular it is possible to detect whether one of the determined speed values is too high.
Furthermore, FIG. 2 shows one of a plurality of drive motors M which move the measuring device 22 . In order to control the motor M, a power stage PS is provided. In addition, a tachogenerator TG is combined with the motor M or with a shaft which is driven by the motor M and it supplies a tachosignal as a function of the rotational speed of the shaft and therefore as a function of the speed of the measuring device 22 which is moved by the motor M, said tachosignal being a measure of the speed. The tachosignal is fed, on the one hand, to the power stage PS (which can have controllers such as a power controller and a rotational speed controller) in order to control the motor current in accordance with a setpoint value which is fed to the power stage PS. More details are given on an exemplary embodiment of the motor controller with reference to FIG. 3 .
The setpoint speed can be determined (in each case separately for the three coordinate axes) from position setpoint values and additionally from information about the speed at which the measuring device 22 is to be moved in its current position. An example of the use of position setpoint values for controlling a coordinate measuring appliance is known from EP 084 965 4.
The tachosignal or a further-processed signal which is derived therefrom is fed to the second determining device 34 , which determines the speed of the measuring device 22 therefrom. In this context it is also possible, for example, to take into account various transmission stages of a transmission (not illustrated in FIG. 2 ) which is arranged between the motor M and the measuring device 22 .
If at least one of the determining devices 32 , 34 generates a fault signal, said signal is fed to an actuating device 36 which automatically initiates corresponding measures. More details on an exemplary embodiment of such measures are given with reference to FIG. 4 . The actuating device in this exemplary embodiment is a relay or a combination of relays with the associated control device.
The arrangement illustrated in FIG. 3 shows a few details indicating how one of the electric motors M of a coordinate measuring appliance, for example the coordinate measuring appliance described with reference to FIGS. 1 and 2 , is supplied with current during operation and controlled. The motor M is connected in the exemplary embodiment to a power stage PS via two electrical connections C 1 , C 2 . The power stage PS has a signal input SI via which it receives control signals from, for example, a computer or from a microcontroller. Depending on the control signals, the power stage PS sets the motor current which flows via the lines C 1 , C 2 .
In particular, the setpoint position and the actual position and/or the setpoint speed of the coordinate measuring device can serve as input variables of the total control device. The total control device can have, apart from the output stage, further controllers, for example power controllers, rotational speed controllers and position controllers.
The power stage PS can be supplied with electric power via a power supply connection PN which can be connected to an electric alternating voltage power supply system, a power supply unit EV which has, for example, a transformer and a rectifier, a two-pole relay R 2 and via two electrical connections which connect the power supply unit EV to the power stage PS via the relay R 2 , the power stage PS requiring said electric power to feed the motor current.
The power stage PS has a power measuring device IM or is combined with such a power measuring device with which the motor current flowing through the electrical connections C 1 , C 2 and through the motor M can be measured. In addition, the power stage PS has an actuator element (not illustrated in more detail in FIG. 2 ) for setting the motor current.
In addition, a tachosignal generator TG is provided which generates tachosignals as a function of the movement of the electric motor and transmits them via a signal line SL to the power stage PS. The tachosignal generator is, for example, a resolver or a rotational transformer with just one signal generator.
While the coordinate measuring appliance is operating, the power stage PS therefore sets the motor current in the electrical connections C 1 , C 2 (direct current) in accordance with the control signal present at the control signal input SI (for example an analog direct voltage value in the range −10 V to +10 V), and said power stage PS adjusts the speed to the value predefined by the control signal, in which case the power stage PS continuously or quasi-continuously evaluates the tachosignal generated by the tachosignal transmitter.
According to the preferred embodiment of the invention described here, the power stage PS also has a signal output TS for transmitting the tachosignal to the speed monitoring device. However, the tachosignal can also be transmitted directly from the tachosignal transmitter TG to the speed monitoring device.
If the coordinate measuring appliance has a plurality of motors, in each case one arrangement as illustrated in FIG. 2 is preferably provided for each of the electric motors. However, in this case, the power supply unit EV can, for example, be used jointly for all the arrangements.
The fault signal generated by the speed monitoring means preferably triggers the following process: as quickly as possible a control signal which causes the power stage PS to reverse the motor current (i.e. a motor current which actively brakes the motor) is output to the power stage PS. Furthermore, both the relay R 1 and the relay R 2 are actuated by means of control lines (not illustrated in FIG. 3 ) in order to open both relays R 1 , R 2 . If the two relays are opened, both the power supply of the power stage PS (via the electrical connections C 3 , C 4 ) and the motor current line (electrical connections C 1 , C 2 ) are disconnected. Furthermore, a short circuit of the two motor current connections to which the electrical connections C 1 , C 2 are connected is preferably brought about by means of a short-circuit switch KS (see FIG. 2 ) which is arranged between the relay R 1 and the motor M. It is necessary to ensure here that the short circuit is not produced until the relay R 1 is already opened.
FIG. 4 shows an arrangement whose various possible methods of functioning will be described in more detail later. The arrangement shows a computer PC which has a databus B or is connected to such a databus. In addition, a plurality of microcontrollers MC are connected to the databus. Two of the microcontrollers MC are illustrated in FIG. 4 . As is indicated by three dots it is, however, also possible to provide more microcontrollers, preferably one microcontroller for each electric motor which is to be monitored in the coordinate measuring appliance. However, it is alternatively also possible to provide the same microcontroller for a plurality of electric motors or for all the electric motors.
The lower of the two illustrated microcontrollers MC is assigned, for example, to a specific electric motor M, and this electric motor M is also illustrated in FIG. 4 . This microcontroller MC is connected via a signal connection SV to a power stage PS, for example the power stage PS illustrated in FIG. 3 . In addition, a tachosignal transmitter TG, which is connected to the power stage PS via a signal line SL and which generates a tachosignal according to the movement of the electric motor M, is in turn provided.
Furthermore, in FIG. 4 it is possible to see an electrical line C 11 which leads from a connection P 1 at a first electrical potential to the motor M via at least a first switch SW 1 and at least a second switch SW 2 and supplies the latter with motor current while the motor is operating. A corresponding further electrical line C 21 connects the motor M to a second electrical potential (P 2 ). During normal operation of the electric motor M, the power stage PS controls the motor current through the lines C 11 , C 21 .
As is also apparent from FIG. 4 , the computer PC, which may, for example, be a commercially available personal computer, is connected to the first switch SW 1 via the databus B. In order to activate this switch, it is possible to provide further elements which convert a corresponding control signal of the computer PC, which is transmitted via the databus B, for activating the switch SW 1 . As a result, the computer PC is always capable of switching the switch SW 1 on and off. If the computer PC then detects during the monitoring of the speed (in a way which will be described in more detail below) that the motor current has to be disconnected, the computer PC switches off the switch SW 1 .
Furthermore, the microcontroller MC, which is connected to the power stage PS via the signal connection SV, is capable of switching the second switch SW 2 on and off.
In situations which will be explained further below, the microcontroller switches off the switch SW 2 in order to disconnect the motor current through the motor M.
If this system is formulated in general terms and the specific exemplary embodiment according to FIG. 4 is not adhered to, preferably at least two different control devices are provided which can disconnect the motor current independently of one another. As a result, additional reliability of the operation of the electric motor and of the axle of the coordinate measuring appliance which is driven by it can be achieved.
The embodiments described below relate to the arrangement according to FIG. 4 . Both the computer PC and the microcontroller MC are, as already described with reference to FIG. 4 , capable of taking “emergency-off measures” when a fault which is detected by the speed monitoring means occurs. For this purpose, both devices can not only disconnect the motor current individually and independently of one another but also additionally take the measures described with reference to FIG. 3 , specifically they can disconnect the so-called intermediate circuit (electrical connections C 3 , C 4 in FIG. 2 ) and short-circuit the motor.
The computer PC and the microcontrollers MC therefore each have a separate switch-off path. The micro-controllers MC correspond, for example, to the second determining device illustrated in FIG. 2 . They determine the second value of the speed from the tachosignal of the respective linear axis or coordinate axis of the coordinate system. The first determining device 32 according to FIG. 2 can be implemented by the computer PC, which therefore determines the first value of the speed from the measured values of the coordinate measuring system. The microcontrollers can also be referred to as slave microcontrollers since they are below the hierarchy level of the computer PC in the hierarchy of overall control of the coordinate measuring appliance. It is possible to provide further microcontrollers within the scope of the coordinate measuring system which are each assigned to a coordinate axis and supply the computer PC with the measured values for determining coordinates.
However, with the invention there is generally also the possibility of the first value of the speed and the second value of the speed being determined by means of the same speed determining device, for example by means of the computer. In this case, the first determining device also acquires the tachosignal. The microcontroller or microcontrollers can then be omitted or assume other tasks, for example that of monitoring the functional capability of the computer.
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In a method for reliably monitoring the speed of a moveable coordinate measuring device, a first value of the speed is calculated from measured values of the coordinate measurement system. The measured values contain information on positions of the coordinate measuring device. The measured values are further used to determine the coordinates of a measurement object. A second value of the speed is ascertained from measurement signals of at least one additional movement sensor. The measurement signals can also be used for controlling a drive device of the coordinate measuring device. A fault signal can be generated if the first value and/or the second value deviate from one another, from a predetermined value and/or a limit value according to a predefined criterion.
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BACKGROUND OF THE INVENTION
The present invention provides a light-frame structural connection; in particular, the present invention provides a connector for connecting two light framing members at an acute angle, the connector itself occupying the complementary outside obtuse angle.
There are many connectors in light frame construction for connecting two members orthogonally. The present invention provides a connector that can be used to connect two members to each other and in particular two members that are at an acute angle to each other such as in the creation of brace. The connector is particularly adapted for making a strong connection between members at a variety of acute angles.
The present connector is an improved knee-brace stabilizer that makes a structural connection between a first elongated structural member in the form of knee bracing and a second elongated structural member in the form of columns or beams to help stabilize free-standing structures and to comply with many prescriptive deck bracing requirements such as the American Wood Council's “Design for Code Acceptance 6—Prescriptive Residential Wood Deck Construction Guide”. The connector is particularly adapted for bracing 2×, 4× and 6× in line post-to-beam configurations.
SUMMARY OF THE INVENTION
The present invention provides a connector that has a first substantially planar member connected to a second substantially planar member by means of a fold region or line between the first and second substantially planar members. The fold region allows the first substantially planar member and the second substantially planar member to be bent relative to each other at the fold between them so that the first substantially planar member and the second substantially planar member are disposed at one of an unlimited variety of selected angles to one another. The first substantially planar member has a first longitudinal axis with the fold being at one end of the axis while a distal end of the first substantially planar member is at the opposite end of the axis. The second substantially planar member has a second longitudinal axis with the fold being at one end of the axis while a distal end of the second substantially planar member is at the opposite end of the axis. The distal ends of the two substantially planar members generally face away from each other. Also in the present invention, a first panel member is connected to the first planar member at a first angular juncture or bend line, and a second panel member is connected to the second planar member at a second angular juncture or bend line.
The first bend line is disposed orthogonally to the fold line, and the second bend line is also disposed orthogonally to the fold line, and when the first and second planar members are disposed at an angle of 180 degrees to each other, such that they lie in a single plane, the first and second bend lines are aligned. The first bend line is laterally disposed away from the longitudinal axis of the first substantially planar member and the second bend line is laterally disposed away from the longitudinal axis of the second substantially planar member. The first panel member is disposed at an angle to the first substantially planar member such that they do not lie in the same plane and the second panel is disposed at an angle to the second substantially planar member such that they do not lie in the same plane. The first and second panel members occupy substantially the same plane. Also in the present invention, the first panel member is formed with a proximal end and a distal end with the proximal end disposed near the fold between the first and second members and the distal end disposed away from the fold. Similarly, the second panel member is formed with a proximal end and a distal end with the proximal end disposed near the fold between the first and second members and the distal end disposed away from the fold. The proximal end of the first panel is formed with a first extension that extends away from the first panel member and extends beyond the fold between the first and second members. Similarly, the proximal end of the second panel is formed with a second extension that extends beyond the fold between the first and second members.
It is an object of the present invention to provide a connector that can be manufactured inexpensively. This object is achieved in part by forming the connector from a generally rectangular metal blank, such that the lateral edges of the first and second panel members are aligned when the first and second members are aligned in the same plane. This object is further achieved by forming the first extension of the first panel member by notching the material of the second panel member, and similarly forming the second extension of the second panel member by notching the material of the first panel member.
It is an object of the present invention to provide a connector that is readily configured to connections of various angles.
The present invention also provides a connection between a first elongated framing member and a second elongated framing member, the first connection having a connector that attaches to the first and second framing members by means of fasteners inserted through the connector into the first and second framing members. The first elongated framing member is formed with a first planar attachment face and a lateral attachment face disposed at an angle to the first planar attachment face. The second elongated framing member is formed with a second planar attachment face and a lateral attachment face disposed at an angle to the second planar attachment face. One or both of the first and second elongated framing members is also formed with a planar abutment face when the first and second framing members are connected at an angle of less than ninety degrees.
The abutment face of either the first or second elongated framing members is in an interfacing or abutting relation with either the first planar attachment face of the first elongated framing member, if the abutment face is formed on the second elongated framing member, or it is in an interfacing or abutting relation with the second planar attachment face of the second elongated framing member if the abutment face is formed on the first elongated framing member.
In some circumstances, the connector is attached to coplanar faces of the first and second structural members that are adjacent to each other. In such an arrangement, the connector is unbent, with both the first and second substantially planar members occupying the same plane.
When forming the connection according to the present invention, the first attachment surface of the first structural member interfaces with the attachment surface of the first planar member of the connector, and the second attachment surface of the second structural member interfaces with the attachment surface of the second planar member of the connector, and the fold line between the first and second planar members is disposed at the interface between the first and second elongated members.
At least one of the first and second substantially planar members with an extension for most acute-angle connections will have fasteners in both structural members. When the connection is between adjacent coplanar surfaces, both planar members will have fasteners in both structural members.
The side panel members of the connector have edges that closely face each other in the connector blank and when the connector is unbent. The narrow space between them forms a S-curve that cuts back along the juncture between one side panel member and one of the planar members so that neither side panel member is attached to a planar member immediately adjacent the fold region that separates the two planar members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a connection formed according to the present invention.
FIG. 2 is an exploded perspective view of a connection formed according to the present invention.
FIG. 3 is a side elevation view of a connector formed according to the present invention.
FIG. 4 is a bottom plan view of a connector formed according to the present invention.
FIG. 5 is a top plan view of the sheet metal blank of a connector formed according to the present invention.
FIG. 6 is a bottom plan view of a plurality of connections formed according to the present invention.
FIG. 7 is a side elevation view of a plurality of connections formed according to the present invention.
FIG. 8 is a side elevation view of a plurality of connections formed according to the present invention.
FIG. 9 is a bottom plan view of a plurality of connections formed according to the present invention.
FIG. 10 is a side elevation view of a plurality of connections formed according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , the present invention is a structural connection 1 comprising a first elongated structural member 50 , a second elongated structural member 50 , a plurality of fasteners 4 , and a connector 5 . Preferably, the connector 5 is a knee-brace stabilizer 5 that makes a structural connection 1 between a first elongated structural member 50 in the form of knee bracing 50 and a second elongated structural member 50 in the form of columns 50 or beams 50 to help stabilize free-standing structures and to comply with many prescriptive deck bracing requirements such as the American Wood Council's “Design for Code Acceptance 6—Prescriptive Residential Wood Deck Construction Guide”. The connector 5 preferably braces 2×, 4× and 6× in line post-to-beam configurations.
As is also shown in FIG. 1 , The first elongated structural member 50 preferably has a first attachment surface 201 and a second attachment surface 202 angularly related to the first attachment surface 201 . Preferably, the second elongated structural member 50 has a third attachment surface 301 and a fourth attachment surface 302 angularly related to the third attachment surface 301 .
The plurality of fasteners 4 preferably are eight-penny ( 8 d ) nails; Simpson Strong-Tie Strong—Drive® SD9×1½ (0.131″×1½″) screws can be substituted for eight-penny nails. Preferably, the connector 5 is attached with a total of 12 eight-penny nails. Preferably, the first and second substantially planar members 6 and the first and second panel members 9 are formed with fastener openings 16 that provide the optimal fastener arrangement.
The connector 5 stabilizes the connection 1 between the first elongated structural member 50 and the second elongated structural member 50 in cooperation with the plurality of fasteners 4 .
The connector 5 preferably has first and second substantially planar members 6 , a first panel member 9 , and a second panel member 9 . Preferably, the first and second substantially planar members 6 are formed from a rigid material, preferably galvanized sheet steel. The first substantially planar member 6 preferably includes a first end 7 , the second substantially planar member 6 includes a second end 7 , and there is a fold region 8 disposed between the first end 7 and the second end 7 whereby the first end 7 and the second end 7 are adapted to be disposed at a selectable angle to one another. Preferably, the first substantially planar member 6 is attached to the first attachment surface 201 of the first elongated structural member 50 by at least one fastener 4 between the first end 7 and the fold region 8 , and the second substantially planar member 6 is attached to the third attachment surface 301 of the second elongated structural member 50 by at least one fastener 4 between the second end 7 and the fold region 8 . The connector 5 is preferably factory-formed with the fold region 8 bent at a 45-degree angle. The fold region 8 can be field bent to other angles, with the caveat that it should be field bent only once.
Preferably, the first panel member 9 is disposed near the first end 7 of the first substantially planar member 6 . The first panel member 9 preferably has a first distal end 10 and a first inboard end 11 , the first inboard end 11 adjoining the first substantially planar member 6 at a first angular juncture 12 . Preferably, the second panel member 9 is disposed near the second end 7 , the second panel member 9 having a second distal end 10 and a second inboard end 11 , the second inboard end 11 adjoining the second substantially planar member 6 at a second angular juncture 12 .
The first panel member 9 and the second panel member 9 are preferably divided from from one another near the fold region 8 . Preferably, the first panel member 9 has a first tab extension 13 near the first substantially planar member 6 and the first inboard end 11 and projecting toward the second panel member 9 when the fold region 8 is not folded. The first tab extension 13 is preferably attached to one of the second attachment surface 202 and the fourth attachment surface 302 by at least one fastener 4 . Preferably, the second panel member 9 has a second tab extension 13 near the second distal end 10 and projecting toward the first panel member 9 when the fold region 8 is not folded, the second tab extension 13 also being attached to one of the second attachment surface 202 and the fourth attachment surface 302 by at least one fastener 4 .
The first tab extension 13 preferably lies between the second tab extension 13 and the substantially planar member 6 when the fold region 8 is not folded. The spacial relationships of the constituent parts of the connector 5 of course change as the angle of fold region 8 is changed.
As shown in FIG. 5 , preferably the first panel member 9 and the second panel member 9 are bounded by a rectangle 100 when the fold region 8 is not folded. As seen in FIG. 5 , the flat blank 17 of the entire connector 5 is substantially rectangular, so that material waste is minimized in manufacturing. The connector 5 is preferably formed on automated sheet metal forming machinery.
The width of the first panel member 9 between the first distal end 10 and the first inboard end 11 is preferably the same as the width of the second panel member 9 between the second distal end 10 and the second inboard end 11 . Preferably, the first tab extension 13 and the second tab extension 13 are together substantially as wide as the first panel member 9 between the first distal end 10 and the first inboard end 11 . The first tab extension 13 and the second tab extension 13 preferably are together substantially as wide as the second panel member 9 between the second distal end 10 and the second inboard end 11 .
Preferably, at least one of the first tab extension 13 and the second tab extension 13 extends past the fold region 8 . The fold region 8 laterally divides the first and second substantially planar members 6 and one or both of the first and second tab extensions 13 can reach past that division alongside the first and second substantially planar members 6 .
The first panel member 9 and the second panel member 9 are preferably separated by a narrow s-curved gap 15 when the fold region 8 is not folded. When the connector 5 is folded, the first and second panel members 9 draw away from each other but the first and second tab extensions 13 remain in close proximity as one rotates around the end of the other.
Preferably, the first panel member 9 is substantially planar and the second panel member 9 is also substantially planar. The first panel member 9 is preferably orthogonal to the portion of the first substantially planar member 6 between the first end 7 and the fold region 8 . Preferably, the second panel member 9 is also orthogonal to the portion of the second substantially planar member 6 between the second end 7 and the fold region 8 . The fold region 8 preferably can be folded to any angle between 180 degrees and 90 degrees.
Preferably, the substantially planar member 6 of the connector 5 is embossed. The substantially planar member 6 of the connector 5 preferably has a first embossment 14 between the first end 7 and the fold region 8 , at least one fastener 4 is located within the first embossment 14 . The substantially planar member 6 of the connector 5 preferably has a second embossment 14 between the second end 7 and the fold region 8 , at least one fastener 4 is located within the second embossment 14 . The embossments 14 are preferably formed as annular rectangles with rounded corners with an un-embossed portion inside each annular rectangle where the fasteners 4 are located. The embossments 14 preferably are discrete elements that do not cross the fold region 8 .
Preferably, one of the first elongated structural member 50 and the second elongated structural member 50 is a vertical post. One of the first elongated structural member 50 and the second elongated structural member 50 preferably is a vertical post and the other of the first elongated structural member 50 and the second elongated structural member 50 is a diagonal bracing member. Alternatively, one of the first elongated structural member 50 and the second elongated structural member 50 is a vertical post and the other of the first elongated structural member 50 and the second elongated structural member 50 is a horizontal beam.
Preferably, at least one of the first panel member 9 and the second panel member 9 is additionally attached to one of the first elongated structural member 50 and the second elongated structural member 50 with a fastener 4 that is not in its corresponding tab extension 13 .
At least one of the first panel member 9 and the second panel member 9 is preferably attached to one of the first elongated structural member 50 and the second elongated structural member 50 with the fastener 4 that is in its corresponding tab extension 13 , and the same panel member 9 is attached to the other of the first elongated structural member 50 and the second elongated structural member 50 with the fastener 4 that is not in its corresponding tab extension 13 .
Preferably, both the first and second tab extensions 13 extend past the fold region 8 . The first panel member 9 and the second panel member 9 are preferably separated by a narrow gap 15 when the fold region 8 is not folded. Preferably, the first angular juncture 12 does not extend to the fold region 8 such that the narrow gap 15 also separates the first panel member 9 from the first substantially planar member 6 between the fold region 8 and the first end 7 of the substantially planar member 6 adjacent the fold region 8 . This effectively separates the first tab extension 13 from the first substantially planar member 6 , and not joining the first panel member 9 to the substantially planar member 6 adjacent the fold region 8 substantially increases the strength of the connector 5 because the connector 5 would otherwise be prone to failure by tearing along the first angular juncture 12 adjacent the fold region 8 .
As shown in FIG. 1 , in most connections 1 typically made with the connector 5 , one of the first elongated structural member 50 and the second elongated structural member 50 has an end surface 400 that abuts one of the attachment surfaces 201 or 301 of the other of the first elongated structural member 50 and the second elongated structural member 50 . As shown in FIGS. 6 , 7 , 8 , 9 and 10 , the typically connection made with the connector 5 of the present invention is a knee brace where an elongated structural member 2 is disposed at an acute angle to two orthogonally disposed elongated structural members 3 , further strengthening the connection between the orthogonally disposed, elongated structural members 3 .
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A connector having a first substantially planar member connected to a second substantially planar member by means of a fold line between the first and second members that allows the first member and the second member to be bent across the fold line such that the first member and the second member are disposed at one of a variety of selected angles to one another.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of U.S. application Ser. No. 09/634,900 filed Aug. 9, 2000 and entitled Electric Brake Caliper, which application claims priority from U.S. Provisional application Ser. No. 60/167,345, filed Nov. 24, 1999.
TECHNICAL FIELD
[0002] The present invention relates to dragless automotive braking systems of both the hydraulic and electric type incorporating a sliding brake caliper assembly. More particularly, the dragless brake caliper assembly of the present invention substantially reduces, if not altogether eliminates, brake drag, by incorporating an antirotation ballscrew therein, in place of the typical piston assembly presently used in calipers of the electric and hydraulic type.
BACKGROUND OF THE INVENTION
[0003] Heretofore, automotive brake assemblies, both of the hydraulic and electric caliper type, have inherently incorporated drag during braking which decreases fuel economy, shortens the useful life of brake linings, and complicates required brake suspension design to accommodate for the drag created by the assembly.
[0004] Accordingly, there is a need in the industry for a dragless brake caliper assembly, which will overcome shortfalls inherent in the prior art.
[0005] An exemplary brake caliper of the electric type to which the improvement of the subject application applies is disclosed in U.S. application Ser. No. 09/634,900 filed on Aug. 9, 2000 and entitled Electric Brake Caliper, the teachings of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0006] According to the invention there is provided a brake caliper assembly comprising at least an inner brake assembly mounted to a reciprocable actuating mechanism and an outer brake assembly mounted to a sliding caliper housing, the actuating mechanism and the sliding caliper housing being mechanically engaged in a manner to move opposite each other about a wheel rotor positioned between the brake assemblies, the actuating mechanism comprising a driven ballscrew reciprocating between a predefined home position retracting both brake assemblies and a predefined braking position engaging the assemblies against the rotor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of the brake caliper assembly of the present invention as viewed toward an inner caliper of the assembly;
[0008] [0008]FIG. 2 is a perspective view of the brake caliper assembly of the present invention as viewed toward an outer caliper of the assembly;
[0009] [0009]FIG. 3 is a perspective view of the brake caliper assembly of the present invention as viewed toward a housing of the caliper assembly; and
[0010] [0010]FIG. 4 is a perspective view of the brake caliper assembly of the present invention as viewed toward a mounting bracket thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] The structure proposed herein, which is equally applicable to both electric and hydraulic brake calipers, incorporates an antirotation ballscrew for activation of the caliper within defined limits, which has been found through empirical testing to significantly reduce, if not altogether eliminate brake drag.
[0012] To provide a simple overview of the functionality of a caliper assembly, the following synopsis is provided.
[0013] Various types of brake systems are known for use in automotive vehicles. Such brake systems include, for example, hydraulic brakes, anti-lock brakes and electric brakes. Electric brake systems (also referred to as “brake by wire” systems) utilize caliper mechanisms that incorporate an electric motor for driving a gear assembly positioned within the caliper housing, which, in turn, drives an inner brake pad against a brake rotor disc of a vehicle. A second, outer brake pad mounted to the caliper housing is positioned on an opposite side of the rotor disc. During braking, the inner brake pad is forced against the rotor disc and a resulting reactionary force pulls the outer break pad into engagement with the opposite side of the disc. Engagement of the inner and outer brake pads will slow or stop rotation of the rotor disc, and, in turn, slow the vehicle or hold the vehicle in a fixed position.
[0014] A load sensor is typically positioned to detect the amount of force applied by the inner break pad to the rotor disc. This load sensor is operatively coupled to a mechanism for controlling the position of the caliper housing, and in turn, the force applied by the outer break pad to equalize (or “center”) the force applied by the two brake pads on the rotor disc.
[0015] Such caliper assembly includes at least a brake caliper that comprises a caliper housing having a rotor channel adapted to receive a rotor (such as a rotor disc) therein, where the rotor channel has a first axial surface adapted to seat an outer brake pad thereon. The brake caliper also includes a piston assembly mounted to the housing on an axial side of the rotor channel opposite that of the outer brake pad. The piston assembly includes a piston nut, reciprocatable towards and away from the rotor channel, where the piston nut is adapted to seat an inner brake pad thereon, a driven screw threaded into the piston nut, which axially drives the piston nut towards or away from the rotor disc in the rotor channel.
[0016] As illustrated in FIGS. 1 - 4 , the brake caliper assembly 10 of the present invention which is applicable for use in either an electric or hydraulic braking system includes an inner brake assembly 12 comprising an inner brake pad 14 suitably mounted to an inner brake shoe 16 . The inner brake shoe 16 is suitably fixed to a drive mechanism 18 therefore, which in the preferred embodiment disclosed herein comprises a ball nut 19 of a ball screw 20 . An outer brake assembly 22 comprising a brake pad 24 suitably mounted to an outer brake shoe 26 is suitably attached on the other hand, to a caliper housing 28 via the brake shoe 26 . A caliper bracket 30 is also incorporated into the assembly 10 , the bracket 30 serving as a brake pad guide, and a load transfer mechanism, with the caliper housing 28 being mounted on and reciprocably slidable along a mounting rod 31 of the bracket 30 within predefined limits.
[0017] In operation, during application of the brakes by a driver through brake pedal (not shown) actuation, the inner brake assembly 12 is moved toward outer brake assembly 22 driving brake pad 14 mounted to brake shoe 16 of the assembly 12 against and into an inner rotor face (not shown). Reactionary force, due to mechanical engagement between the ballscrew 20 and the caliper housing 28 , causes the caliper housing 28 to move in a direction opposite that of the ball nut 18 , pulling outer brake assembly 22 attached thereto into an outer rotor face (not shown), with the assemblies 12 and 22 clamping the rotor therebetween and creating desired braking. This scenario, as stated above, is applicable to either hydraulic or electric braking systems.
[0018] Conversely, upon release of the brake pedal by the driver, the brake assemblies 12 and 22 are pulled away from the rotor by opposite action of the drive mechanism 18 and reaction of the caliper housing 28 , creating a clearance between the assemblies 12 and 22 and the rotor sandwiched therebetween.
[0019] In conventional hydraulic brake assemblies, a hydraulic seal around an actuating piston (not shown) thereof is designed to retract the piston from the rotor somewhat, with retraction being dependent on a sliding bracket suspension, the applied force, and the time duration for rubber to contract, as is known.
[0020] In the assembly 10 of the present invention, however, when the ballscrew 20 is incorporated into the assembly 10 in place of the conventional piston assembly, when the inner brake assembly 12 is retracted and reaches a home position against stop 40 on bracket 30 , an axial load is transferred to the caliper housing 28 slidably mounted to the rod 31 of bracket 30 , moving the housing 28 in a direction opposite that of inner brake assembly 12 retraction and thus simultaneously moving the outer brake assembly 22 away from the rotor, in an action opposite that incurred during brake application, creating a clearance between the brake assemblies 12 and 22 and the rotor therebetween, thereby significantly reducing, if not altogether eliminating brake drag.
[0021] Provision of such a clearance between the brake assemblies 12 and 22 and the rotor, as well the degree of clearance created, is understood to be dependent on rotor run out and acceptable predetermined parameters of rotor to pad clearance. The position of the pads 14 and 24 of the assemblies 12 and 22 , respectively, as they relate to position of the rotor therebetween, may be monitored by a motor position encoder (not shown) or alternatively by a position sensor (not shown) which may be located on the ballscrew 20 itself, if required.
[0022] In the assembly 10 , it is understood that predetermined parameters of rotor to pad clearance also take into account wheel speed, with low speeds requiring a greater degree of clearance and high speeds requiring a lesser degree of clearance.
[0023] As described above, the assembly 10 provides a number of advantages, some of which have been described above and others of which are inherent in the invention. Also modifications may be proposed without departing from the teachings herein. Accordingly the scope of the invention is only to be limited as necessitated by the accompanying claims.
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The dragless brake assembly which can be either hydraulic or electrical incorporates a ballscrew engaged to the inner brake assembly, and an outer brake assembly engaged to a sliding caliper housing, the ballscrew and caliper housing being mechanically engaged to move in directions opposite each other simultaneously between predefined limits for application or release of braking.
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CROSS REFERENCES TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a medical device, and more particularly, is for a flexible interface external micro vacuum chamber tissue expander.
2. Description of the Prior Art
Prior art tissue expander devices utilized a vacuum chamber having one open side which was to be applied externally over and about a specific region of skin tissue having an abnormality, anomaly, irregularity, and the like, or even over a skin tissue void of such mentioned features in order to apply a vacuum thereto so that the skin tissue can be reformed for the purpose of treatment of various sorts. These prior art devices often incorporated a skin tissue contact edge which lies in a plane, i.e., these devices presented a non-flexible flat contact surface edge. These prior art devices were often usually applied to flat skin tissue but were not adept in maintaining suitable contact nor in maintaining a steady and sufficient vacuum when applied to slightly irregular surfaces. Clearly what is need is a tissue expander device which overcomes the disadvantages of the prior art devices and which will have capabilities for flexibly, sealingly and accommodatingly contacting and then applying a suitable vacuum over and about a planar or non-planar skin tissue surface. Such a tissue expander device is provided by the present invention, hereby referred to as a flexible interface external micro vacuum chamber tissue expander.
SUMMARY OF THE INVENTION
The general purpose of the present invention is to provide a flexible interface external micro vacuum chamber tissue expander.
According to one embodiment of the present invention, there is provided a flexible interface external micro vacuum chamber tissue expander including a one-piece vacuum chamber having a top wall, a plurality of side walls continuous with each other and with the top wall and extending downwardly from the top wall, a downwardly facing open cavity formed by the top wall and the plurality of side walls, a plurality of receptor groove segments forming a continuous downwardly open receptor groove extending along the lower edges of the plurality of side walls, and a vacuum passage fitting communicating with the inside of the vacuum chamber. Also included in the present invention is a one-piece open top and open bottom flexible sliding interface having a plurality of walls, each having a top edge and a bottom edge. The flexible sliding interface is slidingly accommodated by the receptor groove at the lower region of the vacuum chamber. The lower edge of the flexible sliding interface is incorporated to flexibly, accommodatingly and sealingly contact irregular and/or regular planar skin tissue or other organ tissue. Vacuum is applied to the combined and mutually engaged vacuum chamber and flexible sliding interface to apply a negative pressure to the interior of the external tissue expander, thereby imparting a negative pressure to the skin or organ tissue where the skin or organ tissue is expanded into the open interior of the external tissue expander. Subsequent to the skin or organ tissue expansion and removal of the external tissue expander, the expanded skin tissue can be treated in various fashions, for example, the external skin tissue can be grafted or injected with fat cells for the purpose of reconstructive or other surgery.
One significant aspect and feature of the present invention is a flexible interface external micro vacuum chamber tissue expander having an open bottom vacuum chamber.
Another significant aspect and feature of the present invention is a flexible interface external micro vacuum chamber tissue expander having an open bottom and open top flexible sliding interface.
Another significant aspect and feature of the present invention is a flexible interface external micro vacuum chamber tissue expander having a flexible sliding interface accommodated by a receptor groove in the lower edge of the vacuum chamber.
Another significant aspect and feature of the present invention is a flexible interface external micro vacuum chamber tissue expander having a flexible sliding interface which flexingly, accommodatingly and sealingly contacts irregular and/or regular skin or organ tissue.
Yet another significant aspect and feature of the present invention is a flexible interface external micro vacuum chamber tissue expander which applies a negative pressure or vacuum to the interior of the vacuum chamber to promote expansion of the skin tissue and closely associated biological material into the interior cavity of the external tissue expander.
Still another significant aspect and feature of the present invention is to alter affected biological structures in preparations for other medical interventions and is designed to elevate and stretch, as well as to expand, reshape and reform tissues such as, but not limited to, skin, that are scarred from trauma, disease or developmental deformities.
Yet another significant aspect and feature of the present invention is to provide a method to expand, reshape and reform the epidermis, subcutaneous fat and connective tissue layer, and the muscle tissue.
Yet another significant aspect and feature of the present invention is to provide a method to alter affected biological structures in preparations for other medical interventions including, but not limited to, subcutaneous injection of biological materials whether manmade or natural.
Having thus briefly described one or more embodiments of the present invention, and having mentioned some significant aspects and features of the present invention, it is the principal object of the present invention to provide a flexible interface external micro vacuum chamber tissue expander
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is a side view in partial cross section showing a flexible interface external micro vacuum chamber tissue expander, the present invention, connected to and in use with a vacuum source, a vacuum delivery tube, and a vacuum gauge;
FIG. 2 is an exploded isometric view generally showing the flexible interface external micro vacuum chamber tissue expander including the one-piece open bottom vacuum chamber, the vacuum passage fitting and the flexible sliding interface;
FIG. 3 is an exploded side view in cross section along line 3 - 3 of FIG. 2 ;
FIG. 4 is an isometric view generally showing the flexible interface external micro vacuum chamber tissue expander including the one-piece open bottom vacuum chamber, the vacuum passage fitting and the flexible sliding interface, and the vacuum passage fitting in engagement with the vacuum chamber;
FIG. 5 is a side view in cross section along line 5 - 5 of FIG. 4 showing the mating of the flexible sliding interface to the vacuum chamber;
FIG. 6 is an isometric view generally showing the tissue expander including the one-piece open bottom vacuum chamber, the vacuum passage fitting and the flexible sliding interface, where the flexible sliding interface is shown in partial phantom lines in mutual engagement with the vacuum chamber;
FIG. 7 is a side view in cross section like FIG. 5 showing the mated flexible sliding interface and vacuum chamber in flexible accommodating contact with tissue;
FIG. 8 is a side view in cross section like FIG. 7 showing the mated flexible sliding interface and vacuum chamber as a unit in flexible contact with skin having a surface that is irregular in contour and variable in texture or consistency where vacuum has been applied; and,
FIG. 9 is a side view in cross section of the outwardly directed reformed and reshaped skin, where a lipo injection device is incorporated to inject grafted fat cells subcutaneously.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a side view in partial cross section showing a flexible interface external micro vacuum chamber tissue expander, the present invention, referred to herein as the tissue expander 10 , connected to and in use with a vacuum source 12 , a vacuum delivery tube 14 and a vacuum gauge 16 . The tissue expander 10 is comprised generally of a one-piece open bottom vacuum chamber 18 , a vacuum passage fitting 20 , and a flexible sliding interface 22 , each component of which is shown and described later in detail in FIG. 2 and other following illustrations that follow.
FIG. 2 is an exploded isometric view generally showing the tissue expander 10 , including the one-piece open bottom vacuum chamber 18 , the vacuum passage fitting 20 , and the flexible sliding interface 22 .
FIG. 3 is an exploded side view in cross section along line 3 - 3 of FIG. 2 . With reference to the preceding figures and with reference to FIG. 3 , the present invention is further described. The vacuum chamber 18 , which can be of plastic or other suitable material, includes a top wall 24 , a plurality of geometrically configured side walls 26 a - 26 n continuous with each other and continuous with the top wall 24 and extending downwardly from the top wall 24 , and an open cavity 28 formed by the inner surfaces of the top wall 24 and the inner surfaces of the plurality of the geometrically configured side walls 26 a - 26 n . The lower regions of the geometrically configured side walls 26 a - 26 n are expanded and of an increased thickness with respect to the upper regions of the geometrically configured side walls 26 a - 26 n and include a plurality of receptor groove segments 30 a - 30 n which form a continuous downwardly open receptor groove 30 extending within and along the lower regions of the plurality of the geometrically configured side walls 26 a - 26 n . The vacuum passage fitting 20 communicates with the cavity 28 of the vacuum chamber 18 in order to impart a negative pressure, i.e., a vacuum, to the interior of the cavity 28 . A pressure relief port 32 is also provided at the top of the receptor groove 30 . The one-piece open top and open bottom flexible sliding interface 22 , which can be of a durometer silicone or other suitable material, includes a plurality of continuously constructed walls 34 a - 34 n continuous with each other having closely associated and corresponding top edges 36 a - 36 n and bottom edges 38 a - 38 n , respectively. Although the top edges 36 a - 36 n and bottom edges 38 a - 38 n , respectively, are shown in planar fashion, such edges, especially the bottom edges 38 a - 38 n , could be of other suitable shapes, such as, but not limited to, semi-circular, semi-oval, one or more grooves, or other suitable configurations, and shall not be limiting to the scope of the invention. The inner surfaces of the walls 34 a - 34 n delineate an open top and an open bottom cavity 40 , such cavity extending therebetween. Additionally, the overall structures of the invention are shown having a square profile, but such structures can be of other geometric shapes and styles consistent with the principles of the invention, such as round, ovoid or other irregular or regular shaped profiles, and shall not be limiting to the scope of the invention.
FIG. 4 is an isometric view generally showing the tissue expander 10 , including the one-piece open bottom vacuum chamber 18 , the vacuum passage fitting 20 and the flexible sliding interface 22 in engagement with the vacuum chamber 18 .
FIG. 5 is a side view in cross section along line 5 - 5 of FIG. 4 showing the mating of the flexible sliding interface 22 to the vacuum chamber 18 . In particular, the walls 34 a and 34 n of the flexible sliding interface 22 are shown in partial sliding engagement with the receptor groove segments 30 a and 30 n at the lower regions of the geometrically configured side walls 26 a and 26 n of the vacuum chamber 18 . Similar engagement of the walls 34 b and 34 c in partial sliding engagement with the receptor groove segments 30 b and 30 c at the lower regions of the geometrically configured side walls 26 b and 26 c of the vacuum chamber 18 occurs in a like and similar manner, wherein the engagement of the top edges 36 a - 36 n of the walls 34 a - 34 n and the upper regions of the walls 34 a - 34 n of the flexible sliding interface 22 is continuous within the receptor groove 30 which is formed by the receptor groove segments 30 a - 30 n.
FIG. 6 is an isometric view generally showing the tissue expander 10 , including the one-piece open bottom vacuum chamber 18 , the vacuum passage fitting 20 , and the flexible sliding interface 22 , where the flexible sliding interface 22 is shown in partial phantom lines in mutual engagement with the vacuum chamber 18 .
MODE OF OPERATION
FIG. 7 is a side view in cross section similar to FIG. 5 showing the combined and mated vacuum chamber 18 and flexible sliding interface 22 in flexible and conforming contact with tissue having a surface that is irregular in contour and variable in texture or consistency. In this example, the tissue expander 10 is shown in close intimate contact with the surface of skin 42 having surface characteristics as just described. Layers depicted beneath and contained in the skin 42 include at least the epidermis 44 , a subcutaneous fat and connective tissue layer 46 , a plurality of fat cells 48 included in the subcutaneous fat and connective tissue layer 46 , and muscle tissue 50 underlying the subcutaneous fat and connective tissue layer 46 . Prior to application of vacuum to the combined vacuum chamber 18 and flexible sliding interface 22 as a unit, the bottom edges 38 a - 38 n of the tissue expander 10 are brought into contact, whether urged by gravity or by applied force with the skin 42 . The walls 34 a - 34 n of the flexible sliding interface 22 flexibly and variably conform to the irregular shape (or planar shape) of the skin 42 , where such vertical upwardly or downwardly flexing movement and geometric reshaping of the portion of the walls 34 a - 34 n within the surrounding receptor groove segments 30 a - 30 n is accommodated by space provided by the receptor groove segments 30 a - 30 n comprising the receptor groove 30 .
FIG. 8 is a side view in cross section similar to FIG. 7 showing the mated flexible sliding interface 22 and vacuum chamber 18 as a unit in flexible contact with skin 42 having a surface that is irregular in contour and variable in texture or consistency where vacuum has been applied by the vacuum source 12 through the vacuum delivery tube 14 and the vacuum passage fitting 20 to the combined cavities 28 and 40 of the vacuum chamber 18 and the flexible sliding interface 22 , respectively, and to the skin 42 . Such application of vacuum is preferably and controllably applied over time, the span of which can be of variable duration depending upon the desired degree of outwardly directed reformation and reshaping of the skin 42 , including the epidermis 44 , the subcutaneous fat and connective tissue layer 46 , and the redistribution of the plurality of fat cells 48 . Vacuum is applied in a range from one to twenty inches of negative pressure, accordingly. A pressure differential exists between the skin 42 and associated components and features thereof and the applied negative pressure (vacuum) at the combined cavities 28 and 40 , whereby the relatively high pressure of the skin 42 and associated components and features assists in reforming, reshaping and urging of the skin 42 and associated components and features migratingly into the relatively low pressure region in the combined cavities 28 and 40 . One desirable result is the expanding, reforming, reshaping and redistribution of the subcutaneous fat and connective tissue layer 46 whereby the spacing between the plurality of fat cells 48 is increased and the density of the connective tissue is decreased in order to accommodate grafted fat cells 52 , as shown in FIG. 9 . During such expanded deforming and urging of the skin, the contacted portion of the reforming skin 42 exerts an upward force against the bottom edges 38 a - 38 n of the flexible sliding interface 22 to cause further accommodational sliding of the flexible sliding interface 22 into the receptor groove 30 . The applied negative pressure sealingly draws the walls 34 a - 34 n of the flexible sliding interface 22 inwardly and against the inwardly located outwardly facing surfaces of the receptor groove segments 30 a - 30 n to effect a seal between the flexible sliding interface 22 and the side walls 26 a - 26 n of the vacuum chamber 18 , as well as enhancing the seal between the bottom edges 38 a - 38 n with the skin 42 and drawing the tissue expander forcibly toward the skin 42 .
FIG. 9 is a side view in cross section of the outwardly directed expanded, reformed and reshaped skin 42 , comprised of the expanded reformed and reshaped epidermis 44 , the expanded reformed and reshaped subcutaneous fat and the expanded reformed and reshaped connective tissue layer 46 , including the expanded and redistributed plurality of fat cells 48 . In this illustration, the tissue expander 10 has been removed from intimate vacuum influenced contact with the reformed and reshaped skin 42 , including the expanded reformed and reshaped features and components described above. Such reforming and reshaping to expand the spacing between the plurality of fat cells 48 and the spacing and density of the connective tissue layer allows sufficient room for injection and accommodation of grafted fat cells 52 therein. In the alternative, insertion of biological materials, whether manmade or natural, can be inserted in close association with the superficial cutaneous structures. Such cutaneous injections can be accomplished by the use of a lipo injection device 54 having a lumen 56 to deliver a plurality of grafted fat cells 52 or other biological materials which stabilize and maintain the expanded reformed and reshaped geometry of the outwardly directed expanded reformed and reshaped skin 42 .
Various modifications can be made to the present invention without departing from the apparent scope thereof
PARTS LIST
10 tissue expander
12 vacuum source
14 vacuum delivery tube
16 vacuum gauge
18 vacuum chamber
20 vacuum passage fitting
22 flexible sliding interface
24 top wall
26 a - n side walls
28 cavity
30 receptor groove
30 a - n receptor groove segments
32 pressure relief port
34 a - n walls
36 a - n top edges
38 a - n bottom edges
40 cavity
42 skin
44 epidermis
46 subcutaneous fat and connective tissue layer
48 fat cells
50 muscle tissue
52 grafted fat cells
54 lipo injection device
56 lumen
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The present invention is a vacuum chamber tissue expander with a flexible sliding interface, which is applied externally over a specific region of tissue to apply a vacuum thereto so that the skin or other organ tissue can be expanded for treatments such as the subcutaneous grafting of fat cells. The flexible sliding interface accommodates and seals against flat or irregular tissue and slides along a mating groove in the vacuum chamber to provide an adjustable seal.
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The present application claims priority to and the benefit of Provisional Application No. 61/351,253, filed Jun. 3, 2010, entitled “METHODS OF MANUFACTURING PRINTED CIRCUIT BOARDS USING INTERNAL STACKED MICRO VIAS TO COUPLE SUBASSEMBLIES”, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to printed circuit boards and methods of manufacturing the same, and more particularly, to printed circuit boards having circuit layers laminated with blind and internal micro via(s) and methods of manufacturing the same.
BACKGROUND
Most electronic systems include printed circuit boards with high density electronic interconnections. A printed circuit board (PCB) may include one or more circuit cores, substrates, or carriers. In one fabrication scheme for the printed circuit board having the one or more circuit carriers, electronic circuitries (e.g., pads, electronic interconnects, etc.) are fabricated onto opposite sides of an individual circuit carrier to form a pair of circuit layers. These circuit layer pairs of the circuit board may then be physically and electronically joined to form the printed circuit board by fabricating an adhesive (or a prepreg or a bond ply), stacking the circuit layer pairs and the adhesives in a press, curing the resulting circuit board structure, drilling through-holes, and then plating the through-holes with a copper material to interconnect the circuit layer pairs.
The curing process is used to cure the adhesives to provide for permanent physical bonding of the circuit board structure. However, the adhesives generally shrink significantly during the curing process. The shrinkage combined with the later through-hole drilling and plating processes can cause considerable stress into the overall structure, leading to damage or unreliable interconnection or bonding between the circuit layers. Thus, there is a need for material and associated processes which can compensate for this shrinkage and can provide for a more stress-free and reliable electronic interconnection between the circuit layer pairs.
In addition, the plating of the through-holes (or vias) with the copper material requires an additional, expensive, and time consuming process sequence that is difficult to implement with a quick turnaround. FIG. 1 is a flowchart of a sequential lamination process for manufacturing a printed circuit board having stacked vias including expensive and time consuming sequential lamination and plating steps. Thus, there is a need to provide for a printed circuit board and a method of manufacturing the same that can be quickly and easily fabricated and/or ensure alignment of the interconnections (or through-holes or micro vias) on the printed circuit board by reducing iterations of key processes to thereby reduce manufacturing time and cost.
SUMMARY
Aspects of embodiments of the invention relate and are directed to systems and methods of manufacturing printed circuit boards using blind and internal micro vias to couple subassemblies. An embodiment of the invention provides a method of manufacturing a printed circuit including attaching a plurality of metal layer carriers to form a first subassembly including at least one copper foil pad on a first surface, applying an encapsulation material onto the first surface of the first subassembly, curing the encapsulation material and the first subassembly; applying a lamination adhesive to a surface of the cured encapsulation material, forming at least one via in the lamination adhesive and the cured encapsulation material to expose the at least one copper foil pad, attaching a plurality of metal layer carriers to form a second subassembly, and attaching the first subassembly and the second subassembly.
Another embodiment of the invention provides a method of manufacturing a multi-layer printed circuit board including forming a first subassembly including (a) attaching at least one metal layer carrier to form a first subassembly including at least one copper foil pad on a first surface, (b) applying an encapsulation material onto the first surface of the first subassembly, (c) curing the encapsulation material and the first subassembly, (d) forming at least one first via in the cured encapsulation material to expose the at least one copper foil pad, (e) forming a conductive pattern on a surface of the cured encapsulation material, the conductive pattern including a conductive pad coupled to the at least one first via, (f) applying a lamination adhesive to the surface of the cured encapsulation material, (g) forming at least one hole in the lamination adhesive proximate the at least one first via, (h) filling the at least one hole with a conductive material to form at least one second via, repeating (a) through (e) to form a second subassembly, attaching the first subassembly and the second subassembly such that the at least one second via of the first subassembly is about aligned with the conductive pad of the second subassembly.
Yet another embodiment of the invention provides an attachment structure for coupling subassemblies of a multi-layer printed circuit board, the structure including a first assembly including a first metal layer carrier including a first blind via including a first capture pad positioned in a top surface of the first metal layer carrier, a first laminate adhesive layer positioned along the top surface and the first capture pad, and a first via about filled with a conductive material positioned in the first laminate adhesive, the first via in contact with the first capture pad, and a second assembly including a second metal layer carrier including a second blind via including a second capture pad positioned in a top surface of the second metal layer carrier, where the first assembly is attached to the second assembly using the first laminate adhesive layer such that the first via in the first adhesive is about aligned with the second capture pad of the second blind via.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart of a sequential lamination process for manufacturing a printed circuit board having stacked vias including sequential lamination and plating steps.
FIGS. 2 a - 2 f illustrate a process for attaching subassemblies to form a multi-layer printed circuit board using internal micro vias positioned in encapsulation and adhesive layers in accordance with one embodiment of the present invention.
FIG. 2 g is a cross sectional view of the finalized multi-layer printed circuit board of FIGS. 2 a - 2 f in accordance with one embodiment of the present invention.
FIG. 3 is a cross sectional view of a multi-layer printed circuit board having three subassemblies attached using the process of FIGS. 2 a - 2 f in accordance with one embodiment of the present invention.
FIGS. 4 a - 4 j illustrate an alternative process for attaching subassemblies to form a multi-layer printed circuit board using internal micro vias positioned in an adhesive layer in accordance with one embodiment of the present invention.
FIG. 5 is a cross sectional expanded view of a subassembly to subassembly attachment including two blind vias coupled by adhesive and conductive paste to form a thin via in accordance with the process of FIGS. 4 a - 4 j.
FIG. 6 is a cross sectional expanded view of another subassembly to subassembly attachment including stacked vias on each subassembly coupled by adhesive and conductive paste to form a via in accordance with one embodiment of the present invention.
FIG. 7 is a cross sectional expanded view of another subassembly to subassembly attachment using a conductive paste micro via located between two mechanically drilled vias having enlarged surface areas in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
In the following detailed description, certain exemplary embodiments of the present invention are shown and described, by way of illustration. As those skilled in the art would recognize, the described exemplary embodiments may be modified in various ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, rather than restrictive. There may be parts shown in the drawings, or parts not shown in the drawings, that are not discussed in the specification as they are not essential to a complete understanding of the invention. Like reference numerals designate like elements.
FIG. 1 is a flowchart of a sequential lamination process for manufacturing a printed circuit board having stacked vias including sequential lamination and plating steps.
FIGS. 2 a - 2 f show a process for manufacturing a printed circuit board including attaching laminated subassemblies using internal micro vias positioned in encapsulation and adhesive layers in accordance with one embodiment of the present invention.
In FIG. 2 a , the process begins when a laminated subassembly 100 having four layers and copper pads (e.g., foil) 102 on both sides is provided. The laminated subassembly 100 further includes two plated or filled through hole vias 104 . The layers of the subassembly can be made of metal, ceramic, or insulating material (e.g., FR4, LCP, Thermount, BT, GPY, such as Teflon, thermally conducting carbon (stablecor), halogen free, etc., where GPY is a laminate that does not fit in the FR4 category, such as polyimide, aziridine cured epoxy, bismalimide, and other electrical grades of laminate). The present invention, however, is not thereby limited. In other embodiments, other suitable substrate and conductive layer materials can be used. In the embodiment shown in FIG. 2 a , the subassembly layers have a thickness ranging from about 3 to 4 mils. However, in other embodiments, the subassembly layers and other components can have other suitable dimensions.
In several embodiments, the laminated subassembly 100 can be manufactured using the process described in FIG. 1 . In other embodiments, the subassembly can be a single lamination subassembly having multiple single metal layer carriers and stacked micro vias. Aspects of single lamination processes for manufacturing circuit boards are further described in U.S. Pat. No. 7,523,545, U.S. Prov. Pat. Appl. No. 61/189,171, and U.S. patent application Ser. No. 12/772,086 the entire content of each of which is incorporated herein by reference.
In the embodiment illustrated in FIG. 2 a , the laminated subassembly 100 includes four metal layers. In other embodiments, the laminated subassembly can include more than or less than three metal layer carriers. In the embodiment illustrated in FIG. 2 a , the laminated subassembly includes two through hole vias. In other embodiments, the laminated subassembly can have more then or less than two vias. In other embodiments, the through hole vias can be replaced with stacked micro vias, buried vias, and/or blind vias.
In FIG. 2 b , the process applies an encapsulation material 106 to a top surface of the laminated subassembly 100 and cures it. In several embodiments, the encapsulation material is a dielectric material. In several embodiments, the curing is achieved by heating the subassembly and encapsulation material thereon at a pre-selected temperature for a pre-selected duration.
The encapsulation material can be any suitable non-cured insulating material, including, without limitation, FR4, LCP, Thermount, BT, GPY, such as Teflon, thermally conducting carbon (stablecor), halogen free, etc., where GPY is a laminate that does not fit in the FR4 category, such as polyimide, aziridine cured epoxy, bismalimide, and other electrical grades of laminate.
In FIG. 2 c , the process applies a laminate adhesive 108 to a top surface of the cured encapsulation material 106 .
In FIG. 2 d , the process forms holes 110 for micro vias by drilling through the laminate adhesive 108 and encapsulation material 106 up to a top surface of the copper pads 102 . Each of the micro vias can be formed by laser drilling (and/or mechanical drilling) holes with a diameter ranging from about 4 to 10 mils. In other embodiments, other suitable techniques for forming via holes can be used. In addition, other via sizes can be used.
In FIG. 2 e , the holes 110 are filled with conductive paste thereby forming micro vias 112 . In some embodiments, the micro vias are filled with copper instead of conductive paste. In one embodiment, conductive paste is used when the via holes are laser drilled and copper is used when the holes are mechanically drilled.
In FIG. 2 f , a second laminated subassembly 200 having copper pads 202 on both sides is provided and brought in proximity to the first laminated subassembly 100 .
FIG. 2 g is a cross sectional view of the finalized multi-layer printed circuit board of FIGS. 2 a - 2 f in accordance with one embodiment of the present invention. In FIG. 2 g , the first and second subassemblies ( 100 , 200 ) are brought together and attached. In some applications it can be difficult to connect and manufacture boards having high aspect ratio vias. By attaching the laminated subassemblies using the process described above, the method of attachment and manufacturing is made much easier. In the embodiment illustrated in FIG. 2 g , the process of FIGS. 2 b - 2 e is performed on the top surface of the first laminated subassembly 100 . In other embodiments, the process of FIGS. 2 b - 2 e is performed on both the top and bottom surfaces of the laminated subassembly 100 to allow for attachment of more than one second subassembly 200 to the first subassembly 100 .
FIG. 3 is a cross sectional view of a multi-layer printed circuit board 300 including three subassemblies attached using the process of FIGS. 2 a - 2 f in accordance with one embodiment of the present invention. In other embodiments, more than three subassemblies can be attached using the processes of FIGS. 2 a - 2 f . The PCB 300 includes three subassemblies having multiple copper pads 302 and through hole vias 304 . The subassemblies are attached by internal micro vias 312 embedded in the encapsulation layers ( 306 - 1 , 306 - 2 ) and adhesive layers ( 308 - 1 , 308 - 2 ). In the embodiment illustrated in FIG. 3 , the subassembly to subassembly attachment is implemented using a micro via filled with a conductive paste. In other embodiments, the subassembly to subassembly attachment can be implemented using a solid copper plated micro via or solid copper through hole via.
FIGS. 4 a - 4 j illustrate an alternative process for attaching subassemblies to form a multi-layer printed circuit board using internal micro vias in accordance with one embodiment of the present invention.
In FIG. 4 a , the process begins when a laminated subassembly 400 having four layers and copper pads (e.g., foil) 402 on both sides is provided. The laminated subassembly 400 further includes two plated or filled blind vias 404 coupled to another two plated or filled blind vias 405 . The layers of the subassembly can be made of metal, ceramic, or insulating material (e.g., FR4, LCP, Thermount, BT, GPY, such as Teflon, thermally conducting carbon (stablecor), halogen free, etc., where GPY is a laminate that does not fit in the FR4 category, such as polyimide, aziridine cured epoxy, bismalimide, and other electrical grades of laminate). The present invention, however, is not thereby limited. In other embodiments, other suitable substrate and conductive layer materials can be used. In the embodiment shown in FIG. 4 a , the subassembly layers have a thickness ranging from about 3 to 4 mils. However, in other embodiments, the subassembly layers and other components can have other suitable dimensions.
In several embodiments, the laminated subassembly 400 can be manufactured using the process described in FIG. 1 . In other embodiments, the subassembly can be a single lamination subassembly having multiple single metal layer carriers and stacked micro vias. Aspects of single lamination processes for manufacturing circuit boards are further described in the above referenced patents and patent applications.
In the embodiment illustrated in FIG. 4 a , the laminated subassembly 400 includes four metal layers. In other embodiments, the laminated subassembly can include more than or less than three metal layer carriers. In the embodiment illustrated in FIG. 4 a , the laminated subassembly includes four blind vias. In other embodiments, the laminated subassembly can have more then or less than four vias. In other embodiments, the blind vias can be replaced with through hole, buried vias, and/or stacked vias.
In FIG. 4 b , the process applies an encapsulation material 406 to a top surface of the laminated subassembly 400 and cures it. In several embodiments, the encapsulation material is a dielectric material. In several embodiments, the curing is achieved by heating the subassembly and encapsulation material thereon at a pre-selected temperature for a pre-selected duration.
The encapsulation material can be any suitable non-cured insulating material, including, without limitation, FR4, LCP, Thermount, BT, GPY, such as Teflon, thermally conducting carbon (stablecor), halogen free, etc., where GPY is a laminate that does not fit in the FR4 category, such as polyimide, aziridine cured epoxy, bismalimide, and other electrical grades of laminate.
In FIG. 4 c , the process forms holes 410 for micro vias (or vias) by drilling through the encapsulation material 406 up to a top surface of the copper pads 402 . Each of the micro vias can be formed by laser drilling (and/or mechanical drilling) holes with a diameter ranging from about 4 to 10 mils. In other embodiments, other suitable techniques for forming via holes can be used. In addition, other via sizes can be used.
In FIG. 4 d , the holes 410 are filled with copper thereby forming solid copper micro vias 412 . In some embodiments, the micro vias 412 are filled with conductive paste instead of copper. In one embodiment, conductive paste is used when the via holes are laser drilled and copper is used when the holes are mechanically drilled.
In FIG. 4 e , the process images, develops, plates copper, adds resist and strips the resist to form a conductive pattern on the encapsulation layer 406 and on vias 412 . The conductive pattern includes capture pads 414 positioned on top of vias 412 .
In FIG. 4 f , the process applies a laminate adhesive 416 to a top surface of the cured encapsulation material 406 and the capture pads 414 .
In FIG. 4 g , the process forms holes 418 for thin micro vias by drilling through the laminate adhesive 416 up to a top surface of the capture pads 414 . Each of the thin micro vias can be formed by laser drilling (and/or mechanical drilling) holes with a diameter ranging from about 1 to 3 mils. In other embodiments, other suitable techniques for forming via holes can be used. In addition, other via sizes can be used.
In FIG. 4 h , the holes 418 are filled with conductive paste thereby forming micro vias 420 .
In FIG. 4 i , a second laminated subassembly 400 - 2 having substantially similar features on one surface thereof to the first subassembly 400 of FIG. 4 e , including two blind solid copper micro vias with conductive pads positioned thereon, is formed and aligned such that the thin conductive paste filled micro vias of the first laminated assembly 400 and corresponding conductive pads of the second laminated assembly 400 - 2 will be physically and electrically coupled when they are brought together for attachment, and secured by the laminate adhesive 416 .
FIG. 4 j is a cross sectional view of the finalized multi-layer printed circuit board of FIGS. 4 a - 4 i in accordance with one embodiment of the present invention. In FIG. 4 j , the first and second subassemblies ( 400 , 400 - 2 ) are brought together and attached. In some applications it can be difficult to connect and manufacture boards having high aspect ratio vias. In some applications, complex via structures can be too difficult to manufacture using traditional manufacturing methods. By attaching the laminated subassemblies using the process described above, the method of attachment and manufacturing is made much easier. In addition, the conductive paste or conductive ink micro via between the laminated subassemblies is very thin (e.g., 3 to 5 mils). While not bound by any particular theory, the thin micro via or joint can provide good high frequency conductivity. In several embodiments, the electrical conductivity of the joint is not as good as a highly conductive metal such as copper. However, because the joint is thin, it can provide the good conductivity for signals having high frequency characteristics (e.g., radio frequency type signals and the like). In addition, the thin copper paste joint can provide minimal disruption to the electrical current flowing therethrough.
In embodiments illustrated in FIGS. 4 a - 4 j , the process is performed on the top surface of the first laminated subassembly 400 . In other embodiments, the process of FIGS. 4 a - 4 j is performed on both the top and bottom surfaces of the laminated subassembly 400 to allow for attachment of more than one second subassembly 400 - 2 to the first subassembly 400 .
In several embodiments, the conductive paste or conductive ink can include a mixture of copper and tin. In other embodiments, other suitable conductive materials can be used for the conductive paste.
FIG. 5 is a cross sectional expanded view of a subassembly to subassembly attachment 500 including two blind vias ( 512 - 1 , 512 - 2 ) coupled by adhesive (not shown) and conductive paste 520 to form a thin via in accordance with the process of FIGS. 4 a - 4 j . Each of the blind vias ( 512 - 1 , 512 - 2 ) includes conductive pads ( 502 - 1 , 502 - 2 ) on outer surfaces thereof and conductive pads ( 514 - 1 , 514 - 2 ) on inner surfaces thereof. The conductive paste structure 520 forms a thin micro via within the adhesive (see FIG. 4 j ), which can have the desirable properties discussed above.
FIG. 6 is a cross sectional expanded view of another subassembly to subassembly attachment 600 including stacked vias ( 602 , 604 ) on each subassembly coupled by adhesive (not shown) and a conductive paste via 606 in accordance with one embodiment of the present invention. As compared to the subassembly attachment of FIG. 5 , the conductive paste via 606 is substantially taller (e.g., z-axis length). This taller form of the conductive paste via can be easier to manufacture and provides good control of the impedance between board layers.
FIG. 7 is a cross sectional expanded view of another subassembly to subassembly attachment 700 using a conductive paste micro via 702 located between two mechanically drilled vias ( 704 , 706 ) having enlarged surface areas ( 708 , 710 ) in accordance with one embodiment of the present invention.
While the above description contains many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as examples of specific embodiments thereof. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents. For example, while certain components have been indicated to be formed of copper, other suitable conductive materials may be used instead of copper.
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Systems and methods of manufacturing printed circuit boards using blind and internal micro vias to couple subassemblies. An embodiment of the invention provides a method of manufacturing a printed circuit including attaching a plurality of metal layer carriers to form a first subassembly including at least one copper foil pad on a first surface, applying an encapsulation material onto the first surface of the first subassembly, curing the encapsulation material and the first subassembly; applying a lamination adhesive to a surface of the cured encapsulation material, forming at least one via in the lamination adhesive and the cured encapsulation material to expose the at least one copper foil pad, attaching a plurality of metal layer carriers to form a second subassembly, and attaching the first subassembly and the second subassembly.
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[0001] This is a divisional of Ser. No. 09/676,730, filed Sep. 29, 2000, which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the field of trenchless underground boring and, more particularly, to a system and method for horizontal drilling and subsurface object detection.
[0003] Utility lines for water, electricity, gas, telephone and cable television are often run underground for reasons of safety and aesthetics. In many situations, the underground utilities can be buried in a trench which is then back-filled. Although useful in areas of new construction, the burial of utilities in a trench has certain disadvantages. In areas supporting existing construction, a trench can cause serious disturbance to structures or roadways. Further, there is a high probability that digging a trench may damage previously buried utilities, and that structures or roadways disturbed by digging the trench are rarely restored to their original condition. Also, an open trench poses a danger of injury to workers and passersby.
[0004] The general technique of boring a horizontal underground hole has recently been developed in order to overcome the disadvantages described above, as well as others unaddressed when employing conventional trenching techniques. In accordance with such a general horizontal boring technique, also known as microtunnelling or trenchless underground boring, a boring system is situated on the ground surface and drills a hole into the ground at an oblique angle with respect to the ground surface. Water is typically flowed through the drill string, over the boring tool, and back up the borehole in order to remove cuttings and dirt. After the boring tool reaches a desired depth, the tool is then directed along a substantially horizontal path to create a horizontal borehole. After the desired length of borehole has been obtained, the tool is then directed upwards to break through to the surface. A reamer is then attached to the drill string which is pulled back through the borehole, thus reaming out the borehole to a larger diameter. It is common to attach a utility line or other conduit to the reaming tool so that it is dragged through the borehole along with the reamer.
[0005] In order to provide for the location of a boring tool while underground, a conventional approach involves the incorporation of an active beacon, typically in the form of a radio transmitter, disposed within the boring tool. A receiver is typically placed on the ground surface and used to determine the position of the tool through a conventional radio direction finding technique. However, since there is no synchronization between the beacon and the detector, the depth of the tool cannot be measured directly, and the position measurement of the boring tool is restricted to a two dimensional surface plane. Moreover, conventional radio direction finding techniques have limited accuracy in determining the position of the boring tool. These limitations can have severe consequences when boring a trenchless underground hole in an area which contains several existing underground utilities or other natural or man-made hazards, in which case the location of the boring tool must be precisely determined in order to avoid accidentally disturbing or damaging the utilities.
[0006] Recently the use of ground penetrating radar (GPR) for performing surveys along trenchless boring routes has been proposed. Ground-penetrating-radar is a sensitive technique for detecting even small changes in the subsurface dielectric constant. Consequently, the images generated by GPR systems contain a great amount of detail, much of it either unwanted or unnecessary for the task at hand. A major difficulty, therefore, in using GPR for locating a boring tool concerns the present inability in the art to correctly distinguish the boring tool signal from all of the signals generated by the other features, such signals collectively being referred to as clutter. Moreover, depending on the depth of the boring tool and the propagation characteristics of the intervening ground medium, the signal from the boring tool can be extremely weak relative to the clutter signal. Consequently, the boring tool signal may either be misinterpreted or undetectable.
[0007] It would be desirable to employ an apparatus for detecting a natural or man-made subsurface feature and controlling an underground excavator to avoid such subsurface feature with greater response time and accuracy than is currently attainable given the present state of the technology.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a system and method of horizontally drilling and subsurface feature detection. According to one embodiment, a horizontal drilling system includes a base machine capable of propelling a drill pipe rotationally and longitudinally underground. A cutting tool system is coupled to the drill pipe, and a control system controls the base machine. A detector is employed to detect a subsurface feature. A communication link is utilized for transferring data between the detector and the control system. The control system uses the data generated by the detector to modify control of the base machine in response to detection of the subsurface feature.
[0009] The subsurface feature may be a geological or man-made obstruction, in which case the control system uses the data generated by the detector to modify control of the base machine to avoid contact between the cutting tool system and the obstruction. The subsurface feature may also comprise a transition between a first subsurface geology and a second subsurface geology, in which case the control system uses the data generated by the detector to modify control of the base machine to modify one or both of cutting tool system direction and base machine propulsion in response to the detected subsurface geology transition. Cutting tool system and/or subsurface feature location and depth may be computed.
[0010] The detector can be integral with the cutting tool system. In such a configuration, the cutting tool includes a cutting element, a power source, a transmitter, and a receiver. In another configuration, the detector is communicatively coupled to the cutting tool system. In a further configuration, the detector operates cooperatively with the cutting tool system to detect the subsurface feature. In yet another configuration, the detector is situated above ground. According to another configuration, elements of the detector are respectively situated at or proximate the cutting tool system and above ground. The detector can include a ground penetrating radar unit, a beacon or an acoustic wave detection unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a side view of a trenchless underground boring apparatus in accordance with an embodiment of the present invention;
[0012] [0012]FIG. 2 is a detailed schematic side view of the trenchless underground boring tool and a probe and detection unit shown in FIG. 1;
[0013] [0013]FIG. 3 is a graph depicting time domain signature signal generation;
[0014] [0014]FIG. 4 is a graph depicting frequency domain signature signal generation;
[0015] [0015]FIGS. 5 a - 5 c show three embodiments for passive microwave signature signal generation;
[0016] [0016]FIGS. 6 a - 6 d show four embodiments for active microwave signature signal generation;
[0017] [0017]FIGS. 7 a - 7 b show two embodiments for active acoustic signature signal generation;
[0018] [0018]FIG. 8 shows an embodiment of a cooperative target incorporating a signature signal generator and an orientation detector;
[0019] [0019]FIG. 9 is an illustration of an orientation detector for detecting an orientation of a cooperative target;
[0020] [0020]FIG. 10 is a block diagram of an orientation detector which, in accordance with one embodiment, detects an orientation of a cooperative target and produces an output indicative of such orientation, and, in accordance with another embodiment, produces an output signature signal that indicates both a location and an orientation of the underground boring tool;
[0021] [0021]FIGS. 11 a - 11 b illustrate an embodiment of an orientation detecting apparatus which includes a number of passive signature signal generating devices that provide both boring tool location and orientation information;
[0022] [0022]FIG. 12 illustrates another embodiment of an orientation detector that produces an output indicative of an orientation of the underground boring tool;
[0023] [0023]FIGS. 13 a - 13 b illustrate another embodiment of a passive orientation detector that produces a signature signal indicative of both the location and orientation of the underground boring tool;
[0024] [0024]FIG. 14 illustrates an embodiment of an orientation detector suitable for incorporation in an underground boring tool that produces an output indicative of the rotational orientation and pitch of the boring tool;
[0025] [0025]FIG. 15 shows an embodiment of a boring tool incorporating an active signature signal generator and an orientation detection apparatus;
[0026] [0026]FIG. 16 is a diagram of a methodology for determining the depth of an underground boring tool incorporating a cooperative target by use of at least two receive antennas and a single transmit antenna;
[0027] [0027]FIG. 17 a is a depiction of an underground boring tool tracking methodology using an array of two receive antennas and a transmit antenna provided within the receive antenna array;
[0028] [0028]FIG. 17 b is a graph illustrating signature signal detection by each of the antennae in the receive antenna array of FIG. 17 a which, in turn, is used to determine a location and deviation of an underground boring tool relative to a predetermined above-ground path;
[0029] [0029]FIG. 18 a is a depiction of an underground boring tool tracking methodology using an array of four receive antennas and a transmit antenna provided within the receive antenna array;
[0030] [0030]FIG. 18 b is a graph illustrating signature signal detection by each of the four antennae in the receive antenna array of FIG. 18 a which, in turn, is used to determine a location and deviation of an underground boring tool relative to a predetermined above-ground path;
[0031] [0031]FIG. 19 is an illustration of a single-axis antenna system typically used with a ground penetrating radar system for providing two-dimensional subsurface geologic imaging;
[0032] [0032]FIG. 20 is an illustration of an antenna system including a plurality of antennae oriented in an orthogonal relationship for use with a ground penetrating radar system to provide three-dimensional subsurface geologic imaging in accordance with one embodiment of the invention;
[0033] [0033]FIG. 21 illustrates an embodiment of a trenchless underground boring tool incorporating various sensors, and further depicts sensor signal information;
[0034] [0034]FIG. 22 illustrates an embodiment of a trenchless underground boring tool incorporating an active beacon and various sensors, and further depicts sensor signal information;
[0035] [0035]FIG. 23 is an illustration of a boring site having a heterogeneous subsurface geology;
[0036] [0036]FIG. 24 is a system block diagram of a trenchless boring system control unit incorporating position indicators, a geographical recording system, various databases, and a geological data acquisition unit;
[0037] [0037]FIG. 25 is an illustration of a boring site and a trenchless boring system incorporating position location devices;
[0038] [0038]FIG. 26 illustrates in flow diagram form generalized method steps for performing a pre-bore survey;
[0039] [0039]FIG. 27 is a system block diagram of a trenchless underground boring system control unit for controlling the boring operation; and
[0040] FIGS. 28 - 29 illustrate in flow diagram form generalized method steps for performing a trenchless boring operation.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0041] Referring now to the figures and, more particularly, to FIG. 1, there is illustrated an embodiment of a trenchless underground boring system incorporating elements for controlling horizontal drilling and subsurface feature detection. In one embodiment, the detection system includes an above-ground probing and detection unit 28 (PDU) and a below-ground cooperative target 20 mounted to, contained in, or otherwise coupled to an underground boring tool 24 .
[0042] The PDU 28 and the target 20 operate in cooperation to provide reliable and accurate locating of an underground boring tool 24 . In addition, the orientation of the boring tool 24 during operation may also be provided. In terms of general operation, the PDU 28 transmits a probe signal 36 into the ground 10 and detects return signals reflected from the ground medium and the underground boring tool 24 . The return signals typically includes content from many different reflection sources, often rendering detection of the underground boring tool 24 unreliable or impossible using conventional techniques. Detecting an underground boring tool 24 is greatly enhanced by use of the cooperative target 20 , which, in response to the probe signal 36 , emits a signature signal that is readily distinguishable from the return signals reflected by the ground medium and the underground boring tool 24 . The cooperative target 20 may also include an orientation detection apparatus that senses an orientation of the boring tool 24 . Boring tool orientation information may be transmitted with the location information as a composite signature signal or as an information signal separate from the signature signal. As such, the presence, location, and orientation of an underground boring tool 24 is readily and reliably determined by employing the probing and detection system and method of the present invention.
[0043] It is well known in the field of subsurface imaging that conventional underground imaging techniques, such as those that employ GPR, detect the presence of many types of underground obstructions and structures. It is also well known in the art that detecting objects of interest, such as an underground boring tool 24 , is often made difficult or impossible due to the detection of return signals emanating from many sources not of interest, collectively known as clutter, associated with other underground obstructions, structures, and varying ground medium characteristics, for example. The clutter signal represents background noise in the composite return signal above which a return signal of interest must be distinguished. Attempting to detect the presence of the underground boring tool 24 using a conventional approach often renders the boring tool 24 undetectable or indistinguishable from the background noise.
[0044] It is understood that the return signal from an underground object of interest using conventional detection techniques may be weak relative to the clutter signal content. In such a case, the signal-to-clutter ratio would be low, which reduces the ability to clearly detect the return signal emanating from the underground object of interest. The probe and detection apparatus and method of the present invention advantageously provides for the production of a return signal from the cooperative target 20 provided at the underground boring tool 24 having a characteristic signature which can be more easily distinguished from the clutter. As will be discussed in detail hereinbelow, the generation of a signature signal containing either or both location and orientation information by the cooperative target 20 may be performed either passively or actively.
[0045] [0045]FIG. 1 illustrates a cross-section through a portion of ground 10 where the boring operation takes place, with most of the components of the detection system depicted situated above the ground surface 11 . The trenchless underground boring system, generally shown as the system 12 , includes a platform 14 on which is situated a tilted longitudinal member 16 . The platform 14 is secured to the ground by pins 18 or other restraining members in order to prevent the platform 14 from moving during the boring operation. Located on the longitudinal member 16 is a thrust/pullback pump 17 for driving a drill string 22 in a forward, longitudinal direction as generally shown by the arrow. The drill string 22 is made up of a number of drill string members 23 attached end-to-end. Also located on the tilted longitudinal member 16 , and mounted to permit movement along the longitudinal member 16 , is a rotating motor 19 for rotating the drill string 22 (illustrated in an intermediate position between an upper position 19 a and a lower position 19 b ). In operation, the rotating motor 19 rotates the drill string 22 which has a boring tool 24 at the end of the drill string 22 .
[0046] A typical boring operation takes place as follows. The rotating motor 19 is initially positioned in an upper location 19 a and rotates the drill string 22 . While the boring tool 24 is rotated, the rotating motor 19 and drill string 17 are pushed in a forward direction by the thrust-pullback pump 20 toward a lower position into the ground, thus creating a borehole 26 . The rotating motor 19 reaches a lower position 19 b when the drill string 22 has been pushed into the borehole 26 by the length of one drill string member 23 . A new drill string member 23 is then added to the drill string 22 either manually or automatically, and the rotating motor 19 is released and pulled back to the upper location 19 a . The rotating motor 19 then clamps on to the new drill string member 23 and the rotation/push process is repeated so as to force the newly lengthened drill string 22 further into the ground, thereby extending the borehole 26 . Commonly, water is pumped through the drill string 22 and back up through the borehole to remove cuttings, dirt, and other debris. If the boring tool 24 incorporates a directional steering capability for controlling its direction, a desired direction can be imparted to the resulting borehole 26 .
[0047] In FIG. 1, there is illustrated a borehole 26 which bends in the vicinity of a point 31 after the initial oblique section becomes parallel to the ground surface 11 . Located above the surface 11 , and detachable from the trenchless underground boring system 12 , is a probing and detection unit 28 (PDU), mounted on wheels 29 or tracks in order to permit above-ground traversing of the PDU 28 along a path corresponding to the underground path of the boring tool 24 . The PDU 28 is coupled to a control unit 32 via a data transmission link 34 .
[0048] The operation of the PDU 28 is more clearly described in reference to FIG. 2. The PDU 28 is generally used to transmit a probe signal 36 into the ground and to detect returning signals. The PDU 28 contains a generator 52 for generating the probe signal 36 which probes the ground 10 . A transmitter 54 receives the probe signal 36 from the generator 52 , which, in turn, transmits the probe signal 36 (shown as continuous lines in FIG. 2) into the ground 10 . In a first embodiment, the generator 52 is a microwave generator and the transmitter 54 is a microwave antenna for transmitting microwave probe signals. In an alternative embodiment, the generator 52 is an acoustic wave generator and produces acoustic waves, and the transmitter 54 is typically a probe placed into the ground 10 to provide for good mechanical contact for transmitting the acoustic waves into the ground 10 .
[0049] The probe signal 36 is transmitted by the PDU 28 , propagates through the ground 10 , and encounters subsurface obstructions, one of which is shown as 30 , which scatter a return signal 40 (shown as dotted lines in FIG. 2) back to the PDU 28 . A signature signal 38 (shown as dashed lines in FIG. 2) is also returned to the PDU 28 from the boring tool 24 located in the borehole 26 .
[0050] The detection section of the PDU 28 includes a receiver 56 , a detector 58 , and a signal processor 60 . The receiver 56 receives the return signals from the ground and communicates them to the detector 58 . The detector 58 converts the return signals into electric signals which are subsequently analyzed in the signal processing unit 60 . In the first embodiment described hereinabove in which the probe signal 36 constitutes a microwave signal, the receiver 56 typically includes an antenna, and the detector 58 typically includes a detection diode. In another embodiment in which the probe signal 36 constitutes an acoustic wave, the receiver 56 typically is a probe in good mechanical contact with the ground 10 and the detector 58 includes a sound-to-electrical transducer, such as microphone. The signal processor 60 may include various preliminary components, such as a signal amplifier, a filtering circuit, and an analog-to-digital converter, followed by more complex circuitry for producing a two or three dimensional image of a subsurface volume which incorporates the various underground obstructions 30 and the boring tool 24 . The PDU 28 also contains a beacon receiver/analyzer 61 for detecting and interpreting a signal from an underground active beacon. The function of the beacon receiver/analyzer 61 will be described more fully hereinbelow.
[0051] The PDU 28 also contains a decoder 63 for decoding information signal content that may be encoded on the signature signal produced by the cooperative target 20 . Orientation, pressure, and temperature information, for example, may be sensed by appropriate sensors provided in the cooperative target 20 , such as a strain gauge for sensing pressure. Such information may be encoded on the signature signal, such as by modulating the signature signal with an information signal, or otherwise transmitted as part of, or separate from, the signature signal. When received by the receiver 56 , an encoded return signal is decoded by the decoder 61 to extract the information signal content from the signature signal content. It is noted that the components of the PDU 28 illustrated in FIG. 2 need not be contained within the same housing or supporting structure.
[0052] Referring once again to FIG. 1, the PDU 28 transmits acquired information along the data transmission link 34 to the control unit 32 , which is illustrated as being located in proximity to the trenchless underground boring system 12 . The data transmission link 34 is provided to handle the transfer of data between the PDU 28 and the trenchless underground boring system 12 , and may be a co-axial cable, an optical fiber, a free-space link for infrared communication, or some other suitable data transfer medium or technique. A significant advantage of using a trenchless underground boring system 12 which employs the subsurface detection technique described herein concerns the detection of other important subsurface features which may purposefully be avoided by the boring tool 24 , particularly buried utilities such as electric, water, gas, sewer, telephone lines, cable lines, and the like.
[0053] Signature signal generation, in accordance with the embodiments of FIGS. 3 and 4, may be accomplished using temporal and frequency based techniques, respectively. FIG. 3 is an illustration depicting the generation and detection of an underground boring tool signature signal in the time domain. Line A shows the emission of a probe signal 36 a as a function of signal character plotted against time. Line B shows a return signal 62 a detected by the PDU 28 in the absence of any signature signal generation. The return signal 62 a is depictive of a signal received by the PDU 28 at a time ΔT 1 after emission of the probe signal 36 a, and is represented as a commixture of signals returned from the underground structure 22 and other scatterers. As previously discussed, a low signal-to-clutter ratio makes it very difficult to distinguish the return signal from the underground boring tool 24 .
[0054] Line C illustrates an advantageous detection technique in which cooperation between the cooperative target 22 , provided at the boring tool 24 , and the PDU 28 is employed to produce and transmit a signature signal at a certain time ΔT 2 following illumination with the probe signal 36 a. In accordance with this detection scheme, the return signal 40 a received from the scatterers is detected initially, and the signature signal 38 a received from the underground boring tool 24 is detected after a delay of ΔT 2 . The delay time ΔT 2 is established to be sufficiently long so that the signature signal produced by the cooperative target 20 is significantly more pronounced than the clutter signal at the time of detection. In this case, the signal-to-clutter ratio of the signature signal 38 a is relatively high, thus enabling the signature signal 38 a to be easily distinguished from the background clutter 40 a.
[0055] [0055]FIG. 4 is an illustration depicting the detection of a cooperative target signature signal emitted from an underground boring tool 24 in the frequency domain. Line A illustrates the frequency band 36 b of the probe signal as a function of signal strength plotted against frequency. Line B shows a frequency band 62 b of a return signal received from the underground boring tool 24 in the absence of any cooperative signal generation. It can be seen that the naturally occurring return signals from the underground boring tool 24 and other scatterers 30 share a frequency band 62 b similar to that of the probe signal 36 b. Line C illustrates a case where cooperation is employed between the cooperative target 20 of the underground boring tool 24 and the PDU 28 to produce and transmit a signature signal which has a frequency band 38 b different from that of the scattered return signal 40 b. The difference in frequency band, indicated as Δf, is sufficiently large to move the cooperative target signature signal out of, or at least partially beyond, the scattered signal frequency band 40 b. Thus, the cooperative target signature signal can be detected with relative ease due to the increased signal-to-clutter ratio. It is noted that high pass, low pass, and notch filtering techniques, for example, or other filtering and signal processing methods may be employed to enhance cooperative target signature signal detection.
[0056] It is an important feature of the invention that the underground boring tool 24 be provided with a signature signal-generating apparatus, such as a cooperative target 20 , which produces a signature signal in response to a probe signal transmitted by the PDU 28 . If no such signature signal was produced by the generating apparatus, the PDU 28 would receive an echo from the underground boring tool 24 which would be very difficult to distinguish from the clutter with a high degree of certainty using conventional detecting techniques. The incorporation of a signature signal generating apparatus advantageously provides for the production of a unique signal by the underground boring tool 24 that is easily distinguishable from the clutter and has a relatively high signal-to-clutter ratio. As discussed briefly above, an active or passive approach is suitable for generating the boring tool signature signal. It is understood that an active signature signal circuit is one in which the circuit used to generate the signature signal requires the application of electrical power from an external source, such as a battery, to make it operable. A passive circuit, in contrast, is one which does not utilize an external source of power. The source of energy for the electrical signals present in a passive circuit is the received probe signal itself.
[0057] In accordance with a passive approach, the cooperative target 20 does not include an active apparatus for generating or amplifying a signal, and is therefore generally less complex than an active approach since it does not require the presence of a permanent or replaceable power source or, in many cases, electronic circuitry. Alternatively, an active approach may be employed which has the advantage that it is more flexible and provides the opportunity to produce a wider range of signature response signals which may be more identifiable when encountering different types of ground medium. Further, an active approach reduces the complexity and cost of manufacturing the cooperative target 20 , and may reduce the complexity and cost of the signature signal receiving apparatus.
[0058] Three embodiments of a passive signature signal generating apparatus associated with a microwave detection technique are illustrated in FIG. 5. Each of the embodiment illustrations shown in FIG. 5 includes a schematic of a cooperative target including a microwave antenna and circuit components which are used to generate the signature signal. The three embodiments illustrated in FIGS. 5 a, 5 b, and 5 c are directed toward the generation of the signature signal using a) the time domain, b) the frequency domain and c) cross-polarization, respectively.
[0059] In FIG. 5 a, there is illustrated a cooperative target 20 which includes two antennae, a probe signal receive antenna 66 a, and a signature signal transmit antenna 68 a. For purposes of illustration, these antennae are illustrated as separate elements, but it is understood that microwave transmit/receive systems can operate using a single antenna for both reception and transmission. Two separate antennae are used in the illustration of this and the following embodiments in order to enhance the understanding of the invention and, as such, no limitation of the invention is to be inferred therefrom. The receive antenna 66 a and the transmit antenna 68 a in the physical embodiment of the signature signal generator will preferably be located inside the cooperative target 20 or on its surface in a conformal configuration. For antennae located entirely within the cooperative target 20 , it is understood that at least a portion of the cooperative target housing is made of a non-metallic material, preferably a hard dielectric material, thus allowing passage of the microwaves through at least a portion of the cooperative target housing. A material suitable for this application is KEVLAR®. Antennae that extend outside of the cooperative target housing may be covered by a protective non-metallic material. The antennae, in this configuration, may be made to conform to the housing contour, or disposed in recesses provided in the housing and covered with an epoxy material, for example.
[0060] The illustration of FIG. 5 a shows the signature signal generation apparatus for a microwave detection system operating in the time domain. In accordance with this embodiment, a receive antenna 66 a receives a probe signal 70 a from the PDU 28 , such as a short microwave burst lasting a few nanoseconds, for example. In order to distinguish a signature signal 74 a from the clutter received by the PDU 28 , the received probe signal 70 a passes from the receive antenna 66 a into a time-delaying waveguide 72 a, preferably a co-axial cable, to a transmit antenna 68 a. The signature signal 74 a is then radiated from the transmit antenna 68 a and received by the PDU 28 . The use of the time-delay line, which preferably delays the response from the cooperative target 20 by about 10 nanoseconds, delays radiating the return signature signal 74 a until after the clutter signal received by the PDU 28 has decreased in magnitude.
[0061] In accordance with another embodiment, a single antenna embodiment of the passive time domain signature generator could be implemented by cutting the waveguide at the point indicated by the dotted line 76 a to form a termination. In this latter embodiment, the probe signal 70 a propagates along the waveguide 72 a until it is reflected by the termination located at the cut 76 a, propagates back to the receive antenna 66 a, and is transmitted back to the PDU 28 . The termination could be implemented either as an electrical short, in which case the probe signal 70 a would be inverted upon reflection, or as an open circuit, in which case the probe signal 70 a would not be inverted upon reflection.
[0062] The introduction of a time delay to create the signature signal 74 a makes the underground boring tool 24 appear deeper in the ground than it is in actuality. Since microwaves are heavily attenuated by the ground, ground penetrating radar systems have a typical effective depth range of about 10 feet when employing conventional detection techniques, beyond which point the signal returns are generally too heavily attenuated to be reliably detected. The production of a time delayed signature signal return 74 a from the underground boring tool 24 artificially translates the depth of the underground boring tool 24 to an apparent depth in the range of 10 to 20 feet, a depth from which there is generally no other strong signal return, thus significantly enhancing the signal-to-clutter ratio of the detected signature signal 74 a. The actual depth of the underground boring tool 24 may then be determined by factoring out the artificial depth component due to the known time delay associated with the cooperative target 20 . It is believed that the signature signal generated by a cooperative target 20 may be detectable at actual depths on the order of 100 feet. It is further believed that a signature signal generated by an active device will generally be stronger, and therefore more detectable, than a signature signal produced by a passive device.
[0063] The illustration of FIG. 5 b depicts a signature signal generating apparatus for a microwave detection system operating in the frequency domain. In accordance with this embodiment, a receive antenna 66 b, provided in or on the boring tool 24 , receives a microwave probe signal 70 b from the PDU 28 . The probe signal 70 b is preferably a microwave burst, lasting for several microseconds, which is centered on a given frequency, f, and has a bandwidth of Δf 1 , where Δf 1 /f is typically less than one percent. In order to shift a return signature signal 74 b out of the frequency regime associated with the clutter received by the PDU 28 , the received probe signal 70 b propagates from the receive antenna 66 b along a waveguide 72 b into a nonlinear device 78 b, preferably a diode, which generates harmonic signals, such as second and third harmonics, from an original signal.
[0064] The harmonic signal is then radiated from a transmit antenna 68 b as the signature signal 74 b and is received by the PDU 28 . The PDU 28 is tuned to detect a harmonic frequency of the probe signal 70 b. For a probe signal 70 b of 100 MHz, for example, a second harmonic detector 58 would be tuned to 200 MHz. Generally, scatterers are linear in their response behavior and generate a clutter signal only at a frequency equal to that of the probe signal 70 b. Since there is generally no other source of the harmonic frequency present, the signal-to-clutter ratio of the signature signal 74 b at the harmonic frequency is relatively high. In a manner similar to that discussed hereinabove with respect to the passive time domain embodiment, the passive frequency domain embodiment may be implemented using a single antenna by cutting the waveguide at the point indicated by the dotted line 76 b to form a termination. In accordance with this latter embodiment, the probe signal 70 b would propagate along the waveguide 72 b, through the nonlinear element 78 b, reflect at the termination 76 b, propagate back through the nonlinear element 78 b, propagate back to the receive antenna 66 b, and be transmitted back to the PDU 28 . The polarity of the reflection would be determined by the nature of the termination, as discussed hereinabove.
[0065] The illustration of FIG. 5 c depicts signature signal generation for a microwave detection system operating in a cross-polarization mode. In accordance with this embodiment, the PDU 28 generates a probe signal 70 c of a specific linear polarity which is then transmitted into the ground. The clutter signal is made up of signal returns from scatterers which, in general, maintain the same polarization as that of the probe signal 70 c. Thus, the clutter signal has essentially the same polarization as the probe signal 70 c. A signature signal 74 c is generated in the cooperative target 20 by receiving the polarized probe signal 70 c in a receive antenna 66 c, propagating the signal through a waveguide 72 c to a transmit antenna 68 c, and transmitting the signature signal 74 c back to the PDU 28 . The transmit antenna 68 c is oriented so that the polarization of the radiated signature signal 74 c is orthogonal to that of the received probe signal 70 c. The PDU 28 may also be configured to preferentially receive a signal whose polarization is orthogonal to that of the probe signal 70 c. As such, the receiver 56 preferentially detects the signature signal 74 c over the clutter signal, thus improving the signature signal-to-clutter ratio.
[0066] In a manner similar to that discussed hereinabove with respect to the passive time and frequency domain embodiments, the cross-polarization mode embodiment may be implemented using a single antenna by cutting the waveguide at the point indicated by the dotted line 76 c to form a termination and inserting a polarization mixer 78 c which alters the polarization of the wave passing therethrough. in this latter embodiment, the probe signal would propagate along the waveguide 72 c, through the polarization mixer 78 c, reflect at the termination 76 c, propagate back through the polarization mixer 78 c, propagate back to the receive antenna 66 c and be transmitted back to the PDU 28 . The polarity of the reflection may be determined by the nature of the termination, as discussed previously hereinabove. It is understood that an antenna employed in the single antenna embodiment would be required to have efficient radiation characteristics for orthogonal polarizations. It is further understood that the cross-polarization embodiment may employ circularly or elliptically polarized microwave radiation. It is also understood that the cross-polarization embodiment may be used in concert with either the passive time domain or passive frequency domain signature generation embodiments described previously with reference to FIGS. 5 a and 5 b in order to further enhance the signal-to-clutter ratio of the detected signature signal.
[0067] Referring now to FIG. 6, active signature signal generation embodiments will be described. FIG. 6 a illustrates an embodiment of active time domain signature signal generation suitable for incorporation in a boring tool 24 . The embodiment illustrated shows a probe signal 82 a being received by a receive antenna 84 a which is coupled to a delay-line waveguide 86 a. An amplifier 88 a is located at a point along the waveguide 86 a, and amplifies the probe signal 82 a as it propagates along the waveguide 86 a. The amplified probe signal continues along the delay-line waveguide 86 a to the transmit antenna 90 a which, in turn, transmits the signature signal 92 a back to the PDU 28 . FIG. 6 b illustrates an alternative embodiment of the active time domain signature generator which incorporates a triggerable delay circuit for producing the time-delay, rather than propagating a signal along a length of time-delay waveguide. The embodiment illustrated shows a probe signal 82 b being received by a receive antenna 84 b coupled to a waveguide 86 b. A triggerable delay circuit 88 b is located at a point along the waveguide 86 b. The triggerable delay circuit 88 b operates in the following fashion. The triggerable delay circuit 88 b is triggered by the probe signal 82 b which, upon initial detection of the probe signal 82 b, initiates an internal timer circuit. Once the timer circuit has reached a predetermined delay time, preferably in the range 1-20 nanoseconds, the timer circuit generates an output signal from the triggerable delay circuit 88 b which is used as a signature signal 92 b. The signature signal 92 b propagates along the waveguide 86 b to a transmit antenna 90 b which then transmits the signature signal 92 b to the PDU 28 .
[0068] [0068]FIG. 6 c illustrates an embodiment of an active frequency domain signature generator suitable for incorporation in or on an underground boring tool 24 . The embodiment illustrated shows a probe signal 82 c being received by a receive antenna 84 c coupled to a waveguide 86 c and a nonlinear element 88 c. The frequency-shifted signal generated by the nonlinear element 88 c is then passed through an amplifier 94 c before being passed to the transmit antenna 90 c, which transmits the signature signal 92 c to the PDU 28 . The amplifier 94 c may also include a filtering circuit to produce a filtered signature signal at the output of the amplifier 94 c. An advantage to using an active frequency domain signature signal generation embodiment over a passive frequency domain signature signal generation embodiment is is that the active embodiment produces a stronger signature signal which is more easily detected.
[0069] In a second embodiment of the active frequency domain signature signal generator, generally illustrated in FIG. 6 c, a probe signal 82 c passes through the amplifier 94 c prior to reaching the nonlinear element 88 c. An advantage of this alternative embodiment is that, since the amplification process may take place at a lower frequency, the amplifier may be less expensive to implement.
[0070] A third embodiment of an active frequency domain signature generator suitable for use with an underground boring tool 24 is illustrated in FIG. 6 d. FIG. 6 d shows a receive antenna 84 d coupled through use of a waveguide 86 d to a frequency shifter 88 d and a transmit antenna 90 d. The frequency shifter 88 d is a device which produces an output signal 92 d having a frequency of f 2 , which is different from the frequency, f 1 , of an input signal 82 d by an offset Δf, where f 2 =f 1 +Δf. In accordance with this embodiment, Δf is preferably larger than one half of the bandwidth of the probe signal 82 d, typically on the order of 1 MHz. The frequency shifter 88 d produces a frequency shift sufficient to move the signature signal 92 d out of, or at least partially beyond, the frequency band of the clutter signal, thereby increasing the signal-to-clutter ratio of the detected signature signal 92 d. For purposes of describing these embodiments, the term signature signal embraces all generated return signals from the cooperative target 20 other than those solely due to the natural reflection of the probe signal off of the underground boring tool 24 .
[0071] [0071]FIG. 7 illustrates an embodiment of a signature signal generator adapted for use in a cooperative target 20 provided on or within an underground boring tool 24 where the probe signal is an acoustic signal. In an acoustic time-domain embodiment, as illustrated in FIG. 7 a, an acoustic probe signal 98 a, preferably an acoustic impulse, is received and detected by an acoustic receiver 100 a mounted on the inner wall 96 a of the boring tool 24 . The acoustic receiver 100 a transmits a trigger signal along a trigger line 102 a to a delay pulse generator 104 a. After being triggered, the delay pulse generator 104 a generates a signature pulse following a triggered delay. The signature pulse is passed along the transmitting line 106 a to an acoustic transmitter 108 a, also mounted on the inner wall 96 a of the boring tool 24 . The acoustic transmitter 108 a then transmits an acoustic signature signal 110 a through the ground for detection by the PDU 28 .
[0072] In accordance with an acoustic frequency-domain embodiment, as is illustrated in FIG. 7 b, an acoustic probe signal 98 b, preferably an acoustic pulse having a given acoustic frequency f 3 , is received and detected by an acoustic receiver 100 b mounted on the inner wall 96 b of the boring tool 24 . The acoustic receiver 100 b transmits an input electrical signal corresponding to the received acoustic signal 98 b at a frequency f 3 along a receive line 102 b to a frequency shifter 104 b. The frequency shifter 104 b generates an output electrical signal having a frequency that is shifted by an amount Δf 3 relative to the frequency of the input signal 98 b. The output signal from the frequency shifter 104 b is passed along a transmit line 106 b to an acoustic transmitter 108 b, also mounted on the inner wall 96 b of the boring tool 24 . The acoustic transmitter 108 b then transmits the frequency shifted acoustic signature signal 110 b through the ground for detection by the PDU 28 .
[0073] In FIG. 8, there is illustrated in system block diagram form another apparatus for actively generating in a cooperative target 20 a signature signal that contains various types of information content. In one configuration, the signature signal generating apparatus of the cooperative target 20 includes a receive antenna 41 , a signature signal generator 43 , and a transmit antenna 45 . In accordance with this configuration, a probe signal 37 produced by the PDU 28 is received by the receive antenna 41 and transmitted to a signature signal generator 43 . The signature signal generator 43 alters the received probed signal 37 so as to produce a signature signal that, when transmitted by the transmit antenna 45 , is readily distinguishable from other return and clutter signals received by the PDU 28 . Alternatively, the signature signal generator 43 , in response to the received probe signal 37 , generates a signature signal different in character than the received probe signal 37 . The signature signal transmitted by the transmit antenna 45 differs from the received probe signal 37 in one or more characteristics so as to be readily distinguishable from other return and clutter signals. By way of example, and as discussed in detail hereinabove, the signature signal produced by the signature signal generator 43 may differ in phase, frequency content, polarization, or information content with respect to other return and clutter signals received by the PDU 28 .
[0074] Additionally, as is further illustrated in FIG. 8, the cooperative target 20 may include an orientation detector 47 . The orientation detector 47 is a device capable of sensing an orientation of the cooperative target 20 , and provides an indication of the orientation of the underground boring tool 24 during operation.
[0075] It may be desirable for the operator to know the orientation of the boring tool 24 when adjusting the direction of the boring tool 24 along an underground pathway, since several techniques known in the art for directing boring tools rely on a preferential orientation of the tool. If the boring tool 24 orientation is not known, the boring tool 24 cannot be steered in a preferred direction in accordance with such known techniques that require knowledge of boring tool 24 orientation. It may not be possible to determine the orientation of the boring tool 24 simply from a knowledge of the orientation of the members 23 of the drill string 22 , since one or more members 23 of the drill string 22 may twist or slip relative to one another during the boring operation. Since the boring operation takes place underground, the operator has no way of detecting whether such twisting or slipping has occurred. It may, therefore, be important to determine the orientation of the boring tool 24 .
[0076] The orientation detector 47 produces an orientation signal which is communicated to an encoder 49 , such as a signal summing device, which encodes the orientation signal produced by the orientation detector 47 on the signature signal produced by the signature signal generator 43 .
[0077] The encoded signature signal produced at the output of the encoder 49 is communicated to the transmit antenna 45 which, in turn, transmits the encoded signature signal 39 to the PDU 28 . Various known techniques for encoding the orientation signal on the signature signal may be implemented by the encoder 49 , such as by modulating the signature signal with the orientation signal. It is noted that other sensors may be included within the apparatus illustrated in FIG. 8 such as, for example, a temperature sensor or a pressure sensor. The outputs of such sensors may be communicated to the encoder 49 and similarly encoded on the signature signal for transmission to the PDU 28 or, alternatively, may be transmitted as information signals independent from the signature signal.
[0078] Referring to FIG. 9, there is illustrated an embodiment of an orientation detecting apparatus which may include up to three mutually orthogonally arranged orientation detectors. The orientation detectors 210 , 212 , and 214 are aligned along the x-axis, y-axis, and z-axis, respectively. In accordance with this embodiment, the orientation detector 210 detects changes in orientation with respect to the x-axis, while the orientation detector 212 senses changes in orientation with respect to the y-axis. Similarly, the orientation detector 214 detects changes in orientation with respect to the z-axis. Given this arrangement, changes in pitch, yaw, and roll may be detected when the cooperative target 20 is subject to positional changes. It is noted that a single orientation detector, such as detector 210 , may be used to sense changes along a single axis, such as pitch changes in the boring tool 24 , if multiple axis orientation changes need not be detected. Further, depending on the initial orientation of the cooperative target 20 when mounted to the underground boring tool 24 , two orthogonally arranged orientation detectors, such as orientation detectors 210 and 212 aligned respectively along the x and y-axes, may be sufficient to provide pitch, yaw, and roll information.
[0079] Referring now to FIG. 10, there is illustrated an embodiment of an apparatus for detecting an orientation of an underground boring tool 24 . In accordance with this embodiment, the cooperative target 20 provided on or within the underground boring tool 24 includes a tilt detector 290 that detects changes in boring tool orientation during boring activity. The cooperative target 20 , in addition to producing a signature signal for purposes of determining boring tool location, may include an orientation detector, such as that illustrated in FIG. 10, for purposes of producing and orientation signal representative of an orientation of the cooperative target 20 and, therefore, the underground boring tool 24 .
[0080] In one embodiment, as is illustrated in FIG. 8, the cooperative target 20 includes an orientation detecting apparatus, which produces an orientation signal, and a separate signature signal generator, which produces a signature signal. The signature signal and the orientation signal may be transmitted by the transmit antenna 45 of the cooperative target 20 as two separate information signals or, alternatively, as a composite signal which includes both the signature and orientation signals. Alternatively, the orientation detecting apparatus may produce a single signature signal that is indicative of both the location and the orientation of the cooperative target 20 .
[0081] Referring in greater detail to FIG. 10, there is illustrated a tilt detector 290 coupled to a selector 291 . The tilt detector 290 detects tilting of the cooperative target 20 with respect to one or more mutually orthogonal axes of the boring tool 24 . It is believed that the tilt detector 290 illustrated in FIG. 10 is useful as a sensor that senses the pitch of the boring tool 24 during operation. The range of tilt angles detectable by the tilt detector 290 may be selected in accordance with the estimated amount of expected boring tool tilting for a given application. For example, the tilt detector 290 may detect maximum pitch angles in the range of ±45° relative to horizontal in one application, whereas, in another application, the tilt detector 290 may detect pitch angles in the range of ±90° relative to horizontal, for example. It is to be understood that the tilt detector 290 , as well as other components illustrated in FIG. 10, may be active or passive components.
[0082] As is further illustrated in FIG. 10, a probe signal 235 is received by the receive antenna 234 which, in turn, communicates the probe signal 235 to a selector 291 . The tilt detector 290 and selector 291 cooperate to select one of several orientation signal generators depending on the magnitude of tilting as detected by the tilt detector 290 . In one embodiment, the probe signal 235 is coupled to each of the orientation signal generators P 1 292 through P N 297 , one of which is selectively activated by the tilt detector 290 which incorporates the function of the selector 291 , such as the embodiment illustrated in FIG. 12. In another embodiment, the probe signal 235 is coupled to the selector 291 which activates one of the orientation signal generators P 1 292 through P N 297 depending on the magnitude of tilting detected by the tilt detector 290 .
[0083] By way of example, and in accordance with a passive component implementation, each of the orientation signal generators P 1 292 through P N 297 represent individual transmission lines, each of which produces a unique time-delayed signature signal which, when transmitted by the transmit antenna 244 , provides both location and orientation information when received by the PDU 28 . As such, the orientation detection apparatus in accordance with this embodiment provides both location and orientation information and does not require a separate signature signal generator 43 . In another embodiment, each of the orientation signal generators, such as orientation signal generator P 3 294 , produces a unique orientation signal which is transmitted to an encoder 49 . A signature signal 299 produced by a signature signal generator 43 separate from the orientation detection apparatus may be input to the encoder 49 , which, in turn, produces a composite signature signal 301 which includes both signature signal and orientation signal content. The composite signal 301 is then transmitted to the PDU 28 and decoded to extract the orientation signal content from the signature signal content.
[0084] As discussed previously, the range of tilt angles detectable by the tilt detector 290 and the resolution between tilt angle increments may vary depending on a particular application or use. By way of example, it is assumed that the tilt detector 290 is capable of detecting maximum tilt angles of ±60°. The selector 291 may select orientation signal generator P 1 292 when the tilt detector 290 is at a level or null state (i.e., 0° tilt angle) relative to horizontal. When selected, orientation detector P 1 292 generates a unique orientation signal which is indicative of an orientation of 0°. As previously discussed, the orientation signal may be combined with a signature signal produced by a separate signature signal generator 43 or, alternatively, may provide both signature signal and orientation signal information which is transmitted to the PDU 28 .
[0085] In the event that the tilt detector 290 detects a positive 5° tilt angle change, for example, orientation signal generator P 2 293 is selected by the selector 291 . The orientation signal generator P 2 293 then produces an orientation signal that indicates a positive 5° tilt condition. Similarly, orientation signal generators P 3 294 , P 4 295 , and P 5 296 may produce orientation signals representing detected tilt angle changes of positive 10°, 15°, and 20°, respectively. Other orientation signal generators may be selected by the selector 291 to produce orientation signals representing tilt angle changes in five degree increments between 25° and 60°. Negative tilt angles between 0° and −60° in 5° increments are preferably communicated to the PDU 28 by selection of appropriate orientation signal generators corresponding to the magnitude of negative tilting. It will be appreciated that the range and resolution between tilt angle increments may vary depending on a particular application.
[0086] In FIGS. 11 a and 11 b, there is illustrated another embodiment of an underground boring tool 500 equipped with a signature signal generating apparatus which, in addition to providing location information, provides boring tool orientation information. Referring to FIG. 11 a, the boring tool 500 includes a longitudinal axis 501 about which the boring tool 500 rotates during boring activity. Distributed about the periphery of the boring tool 500 are a number of a signature signal generating devices, such as devices 504 and 508 . In accordance with this embodiment, the signature signal generating devices operate passively and, as such, do not require an external power supply. Each of the signature signal generating devices distributed about the boring tool 500 produces a unique signature signal in response to a received probe signal generated by the PDU 28 .
[0087] As is further illustrated in FIG. 11 b, the boring tool 500 includes a number of elongated recesses or channels within which signature signal generating devices are disposed. In FIG. 11 b, there is shown a cross-sectional view of the boring tool 500 illustrated in FIG. 11 a. A signature signal generating device 504 , such as a co-axial transmission line, for example, is disposed in a recess 502 and encased in a protective material 505 which permits passage of electromagnetic signals therethrough. The protective material 505 fixes the signature signal generating device 504 within the channel 502 . Also shown in FIG. 11 b is a second signature signal generating device 508 similarly disposed in a recess 506 and encased in a protective material 505 . A hard dielectric material, such as KEVLAR®, is a material suitable material for this application.
[0088] During operation, the boring tool 500 is rotated at an appropriate drilling rate which, assuming a full 360° rotation, exposes each of the signature signal generating devices to a probe signal 36 produced by the PDU 28 . When exposed to the probe signal 36 during rotation, each of the signature signal generating devices will emit a characteristic or signature signal 38 in response to the probe signal 36 . As a particular signature signal generating device rotates beyond a reception window within which the probe signal 36 is received and a signature signal 38 generated, the bulk metallic material of the boring tool 500 shields such a signature signal generating device from the probe signal 36 . It may be desirable to situate the signature signal generating devices about the periphery of the boring tool 500 such that the signature signal produced by the signature signal detecting device exposed to the probe signal 36 produces the predominant signature signal 38 received by the PDU 28 . It may further be desirable to provide for a null or dead zone between adjacent signature signal generating devices so that the only signature signal 38 received by the PDU 28 is that produced by a single signature signal generating device currently exposed to the probe signal 38 .
[0089] The type of signature signal generating device, configuration of the boring tool recesses, such as recess 502 , the type of protective material 505 employed, the number and location of signature signal generating devices used, and the rotation rate of the boring tool 500 will typically impact the ability of the PDU 28 to detect the signature signal 38 produced by each of the signature signal generating devices during boring tool rotation.
[0090] Turning now to FIG. 12, there is illustrated an embodiment of an orientation detector suitable for use in both active and passive signature signal generating apparatuses. In one embodiment, a mercury sensor 220 may be constructed having a bent tube 221 within which a bead of mercury 222 moves as the tube 221 tilts within a plane defined by the axes 223 and 225 . Pairs of electrical contacts, such as contacts 227 and 229 , are distributed along the base of the tube 221 . As the tube 221 tilts, the mercury bead 222 is displaced from an initial or null point, generally located at a minimum bend angle of the tube 221 . As the bead 222 moves along the tube base, electrical contact is made between electrical contact pairs 227 and 229 distributed along the tube base. As the amount of tube tilting increases, the mercury bead 222 is displaced further from the null point, thus completing electrical circuit paths for contact pairs located at corresponding further distances from the null point. As such, the incremental change in tilt magnitude may be determined by detecting continuity in the contact pair over which the mercury bead 222 is situated.
[0091] In one embodiment, sixty-four of such contact pairs are provided along the base of the tube 221 to provide 64-bit tilt resolution information. An electrical circuit or logic (not shown) is coupled to the pairs of electrical contacts 227 and 229 which provides an output indicative of the magnitude of tube tilting, and thus an indication of the magnitude of the cooperative target orientation with respect to the plane defined by axes 223 and 225 . It is appreciated that use of a mercury sensor 220 in accordance with this embodiment may require a power source. As such, this embodiment of an orientation detector is appropriate for use in active signature signal generating circuits. It is noted that the range of tilt angles detectable by the mercury sensor 220 is dependent on the bend angle α provided in the bent tube 221 . The bend angle α, as well as the length of the tube 221 , will also impact the detection resolution of mercury bead displacement within the tube 221 .
[0092] In accordance with another embodiment of an orientation detector suitable for use in passive signature signal generating circuits, reference is made to FIGS. 12 and 13 a - 13 b. The illustration of the apparatus depicted in FIG. 12 may be viewed in a context other than that previously described in connection with a mercury sensor embodiment. In particular, a metallic ball or other metallic object 222 is displaced within a tube 221 in response to tilting of the tube 221 within the plane defined by the axes 223 and 225 . The movable contact 222 moves along a pair of contact rails 235 a and 235 b separated by a channel 237 . The rails 235 a and 235 b include gaps 233 which separate one contact rail circuit from an adjacent contact rail circuit. As is illustrated in detail in FIGS. 13 a - 13 b, each of the contact rail circuits is coupled to a pair of contacts 227 and 229 which, in turn, are coupled to a transmission line capable of producing a unique signature signal.
[0093] By way of example, and with particular reference to FIGS. 13 a - 13 b, movable contact 222 is shown moving within the tube 221 between a first position P a and a second position P b in response to tilting of the tube 221 . When the movable contact 222 is at the position P a , continuity is established between contact 227 , contact rail 235 a, movable contact 222 , contact rail 235 b, and contact 229 . As such, the circuit path including the transmission line T 4 230 is closed. A probe signal 235 produced by the PDU 28 is received by the receive antenna 234 which communicates the probe signal along an input waveguide 232 and through the circuit path defined by contact 227 , rail contact 235 a, movable contact 222 , rail contact 235 b, and contact 229 . The received probe signal 235 transmitted to the time-delaying waveguide T 4 230 produces a time-delayed signature signal which is communicated to an output waveguide 242 and to a transmit antenna 244 . The signature signal produced by the waveguide T 4 230 is then received by the PDU 28 . The PDU 28 correlates the signature signal 245 with the selected signature signal waveguide, such as transmission line T 4 230 , and determines the magnitude of tube 221 tilting. Those skilled in the art will appreciate that various impedance matching techniques, such as use of quarter wavelength matching stubs and the like, may be employed to improve impedance matching within the waveguide pathways illustrated in FIGS. 13 a - 13 b.
[0094] Referring now to FIG. 14, there is illustrated another embodiment of an orientation detection apparatus suitable for detecting an orientation of an underground boring tool 510 . In accordance with this embodiment, a number of rotation detectors, such as R 1 512 and R 2 514 , are disposed at various radial locations about the periphery of the boring tool 510 . The rotation detectors detect radial displacement of the boring tool 510 as the boring tool 510 rotates about its longitudinal axis 501 . A pitch detector 516 , oriented parallel with the longitudinal axis 501 of the boring tool 510 , is susceptible to changes in boring tool pitch. In one embodiment, the rotation detectors, such as R 1 512 and R 2 514 , and the pitch detector 516 are accelerometer-type sensors. Alternatively, the rotation and pitch detectors may constitute spring or strain gauge style sensors. Various other known displacement sensor mechanisms may also be employed.
[0095] The magnitude of the responsive of each rotation detector, such as detector R 1 512 , is typically dependent on the radial location of a particular rotation detector relative to earth's gravity vector as the boring tool 24 rotates about the longitudinal axis 501 . The magnitude of the output produced by the pitch detector 516 is typically dependent on the degree of a boring tool pitch off of horizontal relative to the ground surface 11 . The output signal produced by each of the rotation detectors and the pitch detector may be encoded onto the signature signal produced by the signature signal generating apparatus provided on the boring tool 510 or, alternatively, transmitted to the PDU 28 as a separate information signal.
[0096] [0096]FIG. 21 a illustrates yet another embodiment of an orientation sensing apparatus suitable for use with a boring tool 400 . The boring tool 400 incorporates a passive time domain signature signal circuit including a single antenna 402 , connected via a time delay line 404 to a termination 406 , as discussed hereinabove with respect to FIG. 5 a. The circuit illustrated in FIG. 21 a also includes a mercury switch 408 located at a point along the delay line 404 close to the termination 406 . The termination 406 also includes a dissipative load. When the boring tool 400 is oriented so that the mercury switch 408 is open, the time domain signature signal is generated by reflecting an incoming probe signal 407 at the open circuit of the mercury switch 408 . When the boring tool 400 is oriented so that the mercury switch 408 is closed, the circuit from the antenna 402 is completed to the dissipative load 406 through the delay line 404 . The probe signal 407 does not reflect from the dissipative load 406 and therefore no signature signal is generated. The generation of the signature signal 409 received by the PDU 28 is shown as a function of time in FIG. 21 b. The top trace 407 b shows the probe signal 407 , I p , plotted as a function of time.
[0097] As the boring tool 400 rotates and moves along an underground path, the resistance, Rm, of the mercury switch 408 alternates from low to high values, as shown in the center trace 408 b. The regular opening and closing of the mercury switch 408 modulates the signature signal 409 b, I s , received at the surface. The modulation maintains a constant phase relative to a preferred orientation of the boring tool 24 . The lower trace does not illustrate the delaying effects of the time delay line 404 since the time scales are so different (the time delay on the signature signal 409 is of the order of 10 nanoseconds, while the time taken for a single rotation of the boring tool 24 is typically between 0.1 and 1 second). Detection of the modulated signature signal 409 by the PDU 28 allows the operator to determine the orientation of the boring tool head. It is understood that the other embodiments of signature signal generation described hereinabove can also incorporate a mercury switch 408 and, preferably, a dissipative load 406 in order to generate a modulated signature signal 409 for purposes of detecting the orientation of the boring tool 24 .
[0098] In FIG. 15, there is illustrated an apparatus for actively generating a signature signal and an orientation signal in an underground boring tool 24 . There is shown the head of a boring tool 24 a. At the front end of the boring tool 24 a is a cutter 120 for cutting through soil, sand, clay, and the like when forming an underground passage. A cut-away portion of the boring tool wall 122 reveals a circuit board 124 which is designed to fit inside of the boring tool 24 a. Attached to the circuit board 124 is a battery 126 for providing electrical power. Also connected to the circuit board 124 is an antenna 128 which is used to receive an incoming probe signal 36 and transmit an outgoing signature signal 38 . The antenna 128 may be located inside the boring tool 24 a or may be of a conformal design located on the surface of the boring tool 24 a and conforming to the surface contour. The boring tool 24 a may also contain one or more sensors for sensing the environment of the boring tool 24 a. Circuitry is provided in the boring tool 24 a for relaying this environmental information to the control unit 32 situated above-ground. The sensors, such as an orientation sensor 131 , may be used to measure, for example, the orientation of the boring tool 24 a, (pitch, yaw, and roll) or other factors, such as the temperature of the cutting tool head or the pressure of water at the boring tool 24 a.
[0099] In FIG. 15, there is illustrated a sensor 130 , such as a pressure sensor, located behind the cutter 120 . An electrical connection 132 runs from the sensor 130 to the circuit board 124 which contains circuitry for analyzing the signal received from the sensor 130 . The circuit board 124 may modulate the signature signal 38 to contain information relating to the sensor output or, alternatively, may generate separate sensor signals which are subsequently detected and analyzed above-ground. Also depicted is an orientation sensor 131 which produces an orientation signal indicative of an orientation of the boring tool 24 , such as the lateral position or deviation of the boring tool 24 relative to a predefined underground path or, by way of further example, the pitch of the boring tool 24 relative to horizontal.
[0100] A methodology for detecting the depth of a boring tool 24 incorporating a cooperative target 20 in accordance with one embodiment is illustrated in FIG. 16. In accordance with this embodiment, the PDU 28 includes a transmit antenna 250 and two receive antennas, AR 1 252 and AR 2 254 . Each of the receive antennas AR 1 252 and AR 2 254 is situated a known distance 2 m from the transmit antenna AT 250 . It is assumed for purposes of this example that the propagation rate K through the ground medium of interest is locally constant. Although this assumption may introduce a degree of error with respect to actual or absolute depth boring tool, any such error is believed to be acceptable given the typical application or use of the boring tool cooperative detection technique described here. In other applications, absolute depth determinations may be desired. In such a case, the local propagation rate K, or dielectric constant, may be empirically derived, one such procedure being described hereinbelow.
[0101] Returning to FIG. 16, the time-of-flight, t 1 , of the signal traveling between the cooperative target 20 of the boring tool 24 and the receive antenna AR 252 , and between the transmit antenna 250 and the cooperative target 20 of the boring tool 24 is determined when the cooperative target 20 is positioned below the centerline of the antennas AR 1 252 and AT 250 . The travel time of the signal traveling between the cooperative target 20 and the receive antenna AR 2 254 is indicated as the time t 2 . The depth d of the boring tool 24 that incorporates the cooperative target 20 may then be determined by application of the following equations:
d 2 =K 2 ( t 1 2 )− m 2 [1]
d 2 =K 2 ( t 2 2 )−9 m 2 [2]
K 2 ( t 2 2 )− K 2 ( t 1 2 )=8 m 2 [3]
K 2 ( t 2 2 −t 1 2 )=8 m 2 [4]
K 2 =[8 m 2 /( t 2 2 −t 1 2 )] [5]
d 2 =(8 m 2 /( t 2 2 −t 1 2 )]( t 1 2 )− m 2 [6]
d=m [(8 t 1 2 /( t 2 2 −t 1 2 ))−1] 2 [7]
[0102] In accordance with an alternative approach for determining the depth d of a cooperative target 20 , depth calculations may be based on field-determined values for characteristic soil properties, such as the dielectric constant and wave velocity through a particular soil type. A simplified empirical technique that may be used when calibrating the depth measurement capabilities of a particular GPR system involves coring a sample target, measuring its depth, and relating it to the number of nanoseconds it takes for a wave to propagate through the core sample.
[0103] For an embodiment of the invention which uses a microwave probe signal, a general relationship for calculating the depth or dielectric constant from the time of flight measurement is described by the following equation:
T E = T F - T D = ∑ d j ɛ j c [ 8 ]
[0104] where, TE is an effective time-of-flight, which is the duration of time during which a probe signal or signature signal is traveling through the ground; TF is the measured time-of-flight; TD is the delay internal to the cooperative target between receiving the probe signal and transmitting the signature signal; d j is the thickness of the jth ground type above the cooperative target; M j is the average dielectric constant of the jth ground type at the microwave frequency; and c is the speed of light in a vacuum. It is important to know the dielectric constant since it provides information related to the type of soil being characterized and its water content. Having determined the dielectric constant of a particular soil type, the depth of the boring tool 24 traversing through similar soil types can be directly derived by application of the above-described equations.
[0105] A methodology for detecting the location of an underground boring tool 24 as the boring tool 24 creates or otherwise travels along an underground path is illustrated in FIGS. 17 a - 17 b and 18 a - 18 b. With reference to these figures and to FIG. 1, an underground boring operation is depicted in which a boring tool 24 is shown excavating the ground 10 so as to create an underground path or borehole 26 . The drill string 22 is increased in length during the boring operation typically by adding individual drill string members 23 to the drill string 22 in a manner previously discussed. As the drill string length is increased, and the boring tool 24 forced further into the ground 10 , the PDU 28 is moved along a preferred above-ground path 41 at a speed approximately equal to the horizontal speed component of the boring tool 24 .
[0106] In one embodiment, the PDU 28 repeatedly transmits a probe signal 36 into the ground 10 when moved along the path 41 , which is received by the signature signal generating apparatus provided on or within the boring tool 24 . In response to the probe signal 36 , a signature signal 38 is transmitted at the boring tool 24 and received is by the PDU 28 . Any deviation taken by the boring tool 24 from the preferred above-ground path 41 is detected by the PDU 28 . An appropriate course correction may be effected either manually or automatically by the trenchless underground boring system 12 in response to such a deviation, as will be discussed hereinbelow. While effecting a boring tool course change, the PDU 28 is moved along the path 41 so as to continue tracking the progress and direction of the boring tool 24 through the ground 10 . In this manner, cooperation between the PDU 28 , the boring tool 24 , and the above-ground portion of the trenchless underground boring system 12 provide for reliable and accurate navigating and tracking of an underground boring tool 24 during excavation.
[0107] [0107]FIGS. 17 a and 17 b illustrate one embodiment of a detection methodology employing an antenna array 37 coupled to the PDU 28 . The antenna array 37 includes a left receive antenna A L and a right receive antenna A R which are respectively positioned on either side of a transmit antenna (not shown) situated at a mid-point between the two receive antennas A L and A R . The dashed line 41 shown in FIG. 17 a depicts a preferred above-ground path under which a borehole 26 is to be created, or has been created, by a boring tool 24 equipped with a cooperative target 20 . At a first location L 1 , it can be seen that the underground boring tool 24 is located immediately beneath the transmit antenna positioned in the center of the antenna array 37 . A probe signal 36 emitted by the transmit antenna at a time t 0 is received by the cooperative target 20 in the boring tool 24 , which, in turn, produces a signature signal 38 that is received by the left receive antenna A L and the right receive antenna A R at approximately the same time, as is illustrated in the graph G 1 of FIG. 17 b.
[0108] Referring to the graph G 1 of FIG. 17 b, it is assumed that the probe signal 36 produced by the PDU 28 is transmitted at a time t 0 . Because the two receive antennas A L and A R of the antenna array 37 are substantially equidistant relative to the cooperative target 20 , the signature signal produced by the cooperative target 20 is received by the two antennas A L and A R at substantially the same time, t 1 , after transmission of the probe signal at time t 0 . Concurrent reception of the signature signal by the two receive antennas A L and A R is depicted in the graph G 1 of FIG. 17 b as detected signals S R and S L , respectively, at a time t 1 .
[0109] At a second location L 2 along the preferred or predetermined above-ground path 41 , it can be seen that the boring tool 24 has deviated in a direction left (L) of the center (C) of the predetermined path 41 . This deviation of the boring tool 24 is detected by the PDU 28 as a time delay between a time the signature signal 38 is received by the left and right receive antennas A L and A R , respectively. This time delay results from a difference in the separation distance between the boring tool 24 with respect to the left and right receive antennas A L and A R . It can be seen that the separation distance between the left receive antenna A L and the boring tool 24 is less than the separation distance between the right receive antenna A R and the boring tool 24 . The boring tool deviation from the center of path 41 is reflected in the graph G 2 of FIG. 17 b as a delay between reception of the signature signal S L by the left receive antenna A L at a time t 2 and reception of the signature signal S R by the right receive antenna A R at a later time t 3 .
[0110] At a third location L 3 further along the preferred path 41 , it can be seen that the boring tool 24 has deviated to the right (R) of the center (C) of the preferred path 41 . Such a deviation may result from overcompensation when effecting a course change from a left-of-center location, such as from the second location L 2 . The right-of-center drift of the boring tool 24 is detected by the PDU 28 as the relative time delay between signature signal reception by the left and right receive antennas A L and A R , respectively. At the location L 3 , it can be seen that the distance between the boring tool 24 and the right receive antenna A R is less than the distance between the boring tool 24 and the left receive antenna A L . Accordingly, as is indicated in the graph G 3 of FIG. 17 b , the signature signal S R is received by the right receive antenna A R in advance of the signature signal S L received by the left receive antenna A L , thereby resulting in a time delay defined as (t 3 -t 2 ). This relative time delay may be used to determine the magnitude of boring tool deviation from the predetermined path 41 .
[0111] At a fourth location L 4 along the predefined-above-ground path 41 , it can is be seen that the boring tool 24 has been directed to the desired center point location along the path 41 after having deviated to the right of the path center point at the previously discussed location L 3 . As is shown at location L 4 , the boring tool 24 is again orientated immediately below the center point of the antenna array 37 . The signature signal 38 produced by the cooperative target 20 in response to a probe signal 36 emitted from the transmit antenna situated within the antenna array 37 is received substantially concurrently by the left and right receive antennas A L and A R . The graph G 4 of FIG. 17 b demonstrates that the boring tool 24 is once again progressing as desired along the center line of the predetermined path 41 , as evidenced by contemporaneous reception of the signature signal 38 by the left and right receive antennas A L and A R , respectively. It is noted that the depth of the boring tool, d, may be determined by any of the approaches discussed herein above. In addition, orientation of the boring tool 20 may also be detected and determined in a manner previously discussed above.
[0112] [0112]FIGS. 18 a - 18 b illustrate another embodiment of an antenna array configuration which may be employed in combination with the PDU 28 to accurately track the progress of the underground boring tool 24 along an underground path. With reference to FIG. 18 a , an antenna array 37 includes four receive antennas A 1 , A 2 , A 3 , and A 4 . The antenna array 37 also includes a transmit antenna (not shown) situated at a location within the array 37 , typically at a center location. In accordance with this embodiment, the four receive antennas are distributed about the circular array 37 at 0°, 90°, 180°, and 270° positions, respectively. It is to be understood that the configuration of the antenna array 37 need not be circular as is illustrated in the figures, but may instead be arranged in any suitable geometric configuration. Also, the distribution of receive antennas about the antenna array may be different from that illustrated in the figures.
[0113] [0113]FIG. 18 a is a depiction of the antenna array 37 having its center transmit antenna orientated co-parallel with a predetermined above-ground path 41 . Superimposed in FIG. 18 a is an underground boring tool 24 equipped with a cooperative target 20 depicted at three different locations L 1 , L 2 , and L 3 along the predetermined path 41 . At the location L 1 , it can be seen that the boring tool 24 is properly aligned co-parallel with the preferred path 41 . The signature signal produced by the cooperative target 20 , in response to a probe signal produced by the transmit antenna at a time t o , is received at substantially the same time, t 4 , by each of the four receive antennas A 1 , A 2 , A 3 , and A 4 . The in-phase relationship of the signature signals S 1 , S 2 , S 3 , and S 4 respectively received by receive antennas A 1 , A 2 , A 3 , and A 4 is depicted in the graph G 1 of FIG. 18 b.
[0114] At a location L 2 , it can be seen that the boring tool 24 has deviated right-of-center with respect to the path 41 . This course deviation taken by the boring tool 24 is detected by the PDU 28 as an out-of-phase signature signal response within the antenna array 37 . The right-of-center deviation is demonstrated in the graph G 2 of FIG. 18 b by the signature signal reception relationship associated with each of the four receive antennas A 1 , A 2 , A 3 , and A 4 . It can be seen that the distance between the boring tool 24 at location L 2 and the receive antenna A 2 is less than the distance between the boring tool 24 and the other receive antennas A 1 , A 3 , and A 4 . As is depicted in the graph G 2 of FIG. 18 b , the signature signal S 2 is received at a time t 2 by the receive antenna A 2 earlier than the reception times associated with the other receive antennas. By way of further example, the relative distances between the cooperative target 24 and the receive antennas A 1 and A 4 at the previous location L 1 have effectively increased when the boring tool 24 deviates to the location L 2 , thereby increasing the delay time of signature signal reception by receive antennas A 1 and A 4 . As such, reception of the signature signal S 1 by antenna A 1 at a time t 7 and the signature signal S 4 by receive antenna A 4 at a time t 8 is delayed with respect to the reception of signature signal received by receive antennas A 2 and A 3 at times t 2 and t 5 respectively.
[0115] At a location L 3 , the graph G 3 of FIG. 18 b demonstrates that the boring tool 24 has deviated to a left-of-center position relative to the path 41 . The magnitude of the relative time delay within the antenna array 37 indicates the magnitude of off-of-center boring tool deviations as is illustrated by the signature signal response graph of FIG. 18 b. It is noted that the boring tool 24 may deviate beyond the periphery of the antenna array 37 . Such a deviation will result in a more pronounced reduction in the signal-to-noise ratio with respect to receive antennas situated furthest away from the boring tool location. It is understood that an increase in the number of receive antennas within the antenna array 37 provides for a concomitant increase in boring tool detection resolution. It is believed that an antenna array 37 having a diameter ranging between approximately 2 feet and 5 feet is sufficient for detecting the location of the boring tool 24 at depths of approximately 10 to 15 feet or less.
[0116] In order to obtain three-dimensional data, a GPR system employing single-axis antenna must make several traverses over the section of ground or must use multiple antennae. The following describes the formation of two and three dimensional images in accordance with another embodiment of an antenna configuration used in combination with the PDU 28 . In FIG. 19, there is shown a section of ground 500 for which a PDU 28 , typically including a GPR forms an image, with a buried hazard 502 located in the section of ground 500 . The ground surface 504 lies in the x-y plane formed by axes x and y, while the z-axis is directed vertically into the ground 500 . Generally, a single-axis antenna, such as the one illustrated as antenna-A 506 and oriented along the z-axis, is employed to perform multiple survey passes 508 . The multiple survey passes 508 are straight line passes running parallel to each other and have uniform spacing in the y direction. The multiple passes shown in FIG. 19 run parallel to the x-axis.
[0117] Generally, as discussed previously, a GPR system has a time measurement capability which allows measuring of the time for a signal to travel from the transmitter, reflect off of a target, and return to the receiver. After the time function capability of the GPR system provides the operator with depth information, the radar system is moved laterally in a horizontal direction parallel to the x-axis, thus allowing for the construction of a two-dimensional profile of a subsurface. By performing multiple survey passes 508 in a parallel pattern over a particular site, a series of two-dimensional images can be accumulated to produce an estimated three-dimensional view of the site within which a buried hazard may be located. It can be appreciated, however, that the two-dimensional imaging capability of a conventional antenna configuration 506 may result in missing a buried hazard, particularly when the hazard 502 is parallel to the direction of the multiple survey passes 508 and lies in between adjacent survey passes 508 .
[0118] A significant advantage of a geologic imaging antenna configuration 520 of the present invention provides for true three-dimensional imaging of a subsurface as shown in FIG. 20. A pair of antennae, antenna-A 522 and antenna-B 524 , are preferably employed in an orthogonal configuration to provide for three-dimensional imaging of a buried hazard 526 . Antenna-A 522 is shown as directed along a direction contained within the y-z axis and at +45° relative to the z-axis. Antenna-B 524 is also directed along a direction contained within the y-z plane, but at −45° relative to the z-axis, in a position rotated 90° from that of antenna-A 522 . It is noted that the hyperbolic time-position data distribution typically obtained by use of a conventional single-axis antenna, may instead be plotted as a three-dimensional hyperbolic shape that provides width, depth, and length dimensions of a detected buried hazard 526 . It is further noted that a buried hazard 526 , such as a drainage pipeline, which runs parallel to the survey path 528 will readily be detected by the three-dimensional imaging GPR system. Respective pairs of orthogonally oriented transmitting and receive antennae may be employed in the transmitter 54 and receiver 56 of the PDU 28 in accordance with one embodiment of the invention.
[0119] Additional features can be included on the boring tool 24 . It may be desired, under certain circumstances, to make certain measurements of the boring tool 24 orientation, shear stresses on the drill string 22 , and the temperature of the boring tool 24 , for example, in order to more clearly understand the conditions of the boring operation. Additionally, measurement of the water pressure at the boring tool 24 may provide an indirect measurement of the depth of the boring tool 24 as previously described hereinabove.
[0120] [0120]FIG. 21 c illustrates an embodiment which allows sensors to sense the environment of the boring tool 410 . The figure shows an active time domain signature signal generation circuit which includes a receive antenna 412 connected to a transmit antenna 414 through an active time domain circuit 416 . A sensor 418 is connected to the active time domain circuit 416 via a sensor lead 420 . In this embodiment, the sensor 418 is placed at the tip of the boring tool 410 for measuring the pressure of water at the boring tool 410 . The reading from the sensor 418 is detected by the active time domain circuit 416 which converts the reading into a modulation signal. The modulation signal is subsequently used to modulate the actively generated signature signal 415 . This process is described with reference to FIG. 21 d, which shows several signals as a function of time. The top signal 413 d represents the probe signal, I p , received by the receive antenna 412 . The second signal, 415 d, represents the actively generated signature signal I a , which would be generated if there were no modulation of the signature signal. The third trace, 416 d, shows the amplitude modulation signal, I m , generated by the active time domain circuit 416 , and the last trace, 422 d, shows the signature signal, I s , after amplitude modulation. The modulated signature signal 415 is detected by the PDU 28 . Subsequent determination of the modulation signal by the signal processor 60 in the PDU 28 provides data regarding the output from the sensor 418 .
[0121] Modulation of the signature signal is not restricted to the combination of amplitude modulation of a time domain signal as shown in the embodiment of FIG. 21. This combination was supplied for illustrative purposes only. It is understood that other embodiments include amplitude modulation of frequency domain signature signals, and frequency modulation of both time and frequency domain signature signals. In addition, the boring tool 24 may include two or more sensors rather than the single sensor as illustrated in the above embodiment.
[0122] [0122]FIG. 22 a illustrates another embodiment of the invention in which a separate active beacon is employed for transmitting information on the orientation or the environment of the boring tool 430 to the PDU 28 . In this embodiment, shown in FIG. 22 a, the boring tool 430 includes a passive time domain signature circuit employing a single antenna 432 , a time delay line 434 , and an open termination 436 for reflecting the electrical signal. The single antenna 432 is used to receive a probe signal 433 and transmit a signature/beacon signal 435 . An active beacon circuit 438 generates a beacon signal, preferably having a selected frequency in the range of 50 KHz to 500 MHz, which is mixed with the signature signal generated by the termination 436 and transmitted from the antenna 432 as the composite signature/beacon signal 435 . A mercury switch 440 is positioned between the active beacon circuit 438 and the antenna 432 so that the mercury switch 440 operates only on the signal from the active beacon circuit 438 and not on the signature signal generated by the termination 436 .
[0123] When the boring tool 430 is oriented so that the mercury switch 440 is open, the beacon signal circuit 438 is disconnected from the antenna 432 , and no signal is transmitted from the active beacon circuit 438 . When the boring tool 430 is oriented so that the mercury switch 440 is closed, the active beacon circuit 438 is connected to the antenna 432 and the signal from the active beacon circuit 438 is transmitted along with the signature signal as the signature/beacon signal 435 . The effect of the mercury switch on the signature/beacon signal 435 has been described previously with respect to FIG. 21 b. The top trace 438 b, in FIG. 22 b, shows the signal, I b , generated by the active beacon circuit 438 as a function of time. As the boring tool 430 rotates and moves along an underground path, the resistance, Rm, of the mercury switch 440 alternates from low to high values, as shown in the center trace 440 b. The continual opening and closing of the mercury switch 440 produces a modulated signature/beacon signal 435 b, I m , which is received at the surface by the PDU 28 . Only a beacon signal component, and no signature signal component, is shown in signal I m 435 b. The modulation of signal I m 435 b maintains a constant phase relative to a preferred orientation of the boring tool 430 . Analysis of the modulation of the beacon signal by a beacon receiver/analyzer 61 on the PDU 28 allows the operator to determine the orientation of the boring tool head.
[0124] [0124]FIG. 22 c illustrates an embodiment which allows sensors to sense the environment of the boring tool 450 where an active beacon is used to transmit sensor data. The figure shows an active time domain signature signal generation circuit including a receive antenna 452 , a transmit antenna 454 , and an active time domain signature signal circuit 456 , all of which are connected via a time delay line 457 . An active beacon circuit 460 is also connected to the transmit antenna 454 . A sensor 458 is connected to the active beacon circuit 460 via a sensor lead 462 . In this embodiment, the sensor 458 is placed near the tip of the boring tool 450 and is used to measure the pressure of water at the boring tool 450 . The sensor reading is detected by the active beacon circuit 460 which converts the signal from the sensor 458 into a modulation signal. The modulation signal is subsequently used to modulate an active beacon signal generated by the active beacon circuit 460 .
[0125] To illustrate the generation of the signature/beacon signal 455 transmitted to the PDU 28 , several signals are illustrated as a function of time in FIG. 22 d. The signal 453 d represents the probe signal, I p , received by the receive antenna 452 . The second signal 456 d represents the time-delayed signature signal, I s , generated by the active time domain circuit 456 . The third signal 460 d, I c , represents a combination of the time-delayed signature signal I s 456 d and an unmodulated signal produced by the active beacon circuit 460 . The last trace, 455 d, shows a signal received at the surface, I m , which is a combination of the time-delayed signature signal I s 456 d and a signal produced by the active beacon circuit 460 which has been modulated in accordance with the reading from the sensor 458 . Detection of the modulated active beacon signal by the beacon signal detector 61 in the PDU 28 , followed by appropriate analysis, provides data to the user regarding the output from the sensor 458 .
[0126] In FIG. 23, there is illustrated an embodiment for using a detection system to locate an underground boring tool and to characterize the intervening medium between the boring head and the PDU 28 . In this figure, there is illustrated a trenchless underground boring system 12 situated on the surface 11 of the ground 10 in an area in which the boring operation is to take place. A control unit 32 is located near the trenchless underground boring system 12 . In accordance with this illustrative example, a boring operation is taking place under a roadway. The ground 10 is made up of several different ground types, the examples as shown in FIG. 23 being sand (ground type (GT 2 )) 140 , clay (GT 3 ) 142 and native soil (GT 4 ) 144 . The road is generally described by the portion denoted as road fill (GT 1 ) 146 . FIG. 12 illustrates a drill string 22 in a first position 22 c, at the end of which is located a boring tool 24 c. The PDU 28 c is shown as being situated at a location above the boring tool 24 c. The PDU 28 c transmits a probe signal 36 c which propagates through the road fill and the ground.
[0127] In the case of the boring tool at location 24 c, the probe signal 36 c propagates through the road fill 146 and the clay 142 . The boring tool 24 c, in response, produces a signature signal 38 c which is detected and analyzed by the PDU 28 c. The analysis of the signature signal 38 c provides a measure of the time-of-flight of the probe signal 36 c and the signature signal 38 c. The time-of-flight is defined as a time duration measured by the PDU 28 c between sending the probe signal 36 c and receiving the signature signal 38 c. The time-of-flight measured depends on a number of factors including the depth of the boring tool 24 c, the dielectric conditions of the intervening ground medium 146 and 142 , and any delay involved in the generation of the signature signal 38 c. Knowledge of any two of these factors will yield the third from the time-of-flight measurement.
[0128] The depth of the boring tool 24 c can be measured independently using a mechanical probe or sensing the pressure of the water at the boring tool 24 c using a sensor 130 located in the boring tool head 24 c as discussed hereinabove. For the latter measurement, the boring operation is halted, and the water pressure measured. Since the height of the water column in the drill string 22 above the ground is known, the depth of the boring tool 24 c can be calculated using known techniques. For an embodiment of the invention which uses a microwave probe signal, a general relationship for calculating the depth or dielectric constant from the time of flight measurement is given by Equation [8] discussed previously hereinabove.
[0129] For the case where the boring tool is located at position 24 c as shown in FIG. 23, and with the assumption that the road fill has a negligible thickness relative to the thickness of clay, the relationship of Equation [8] simplifies to:
T E = T F - T D = ∑ d 3 ɛ 3 c [ 9 ]
[0130] where, the subscript “3” refers to GT 3 . Direct measurement of the time-of-flight, TF, and the depth of the boring tool 24 c, d 3 , along with the knowledge of any time delay, TD, will yield the average dielectric constant, M 3 , of GT 3 . This characteristic can be denoted as GC 3 .
[0131] Returning to FIG. 23, there is illustrated an embodiment in which the boring tool 24 has been moved from its first location 24 c to another position 24 d. The drill string 22 d (shown in dashed lines) has been extended from its previous configuration 22 c by the addition of extra drill string members in a manner as described previously hereinabove. The PDU 28 has been relocated from its previous position 28 c to a new position 28 d (shown in dashed lines) in order to be close to the boring tool 24 d. The parameter GC 4 , which represents the ground characteristic of the native soil GT 4 , can be obtained by performing time-of-flight measurements as previously described using the probe signal 36 d and signature signal 38 d. Likewise, ground characteristic GC 2 can be obtained from time-of-flight measurements made at the point indicated by the letter “e”. The continuous derivation of the ground characteristics as the boring tool 24 d travels through the ground results in the production of a ground characteristic profile which may be recorded by the control unit 32 . The characteristics of the intervening ground medium between the PDU 28 and the cooperative target 20 may be determined in manner described herein and in U.S. Pat. No. 5,553,407, which is assigned to the assignee of the instant application, the contents of which are incorporated herein by reference.
[0132] It may be advantageous to make a precise recording of the underground path traveled by the boring tool 24 . For example, it may be desirable to make a precise record of where utilities have been buried in order to properly plan future excavations or utility burial and to avoid unintentional disruption of such utilities. Borehole mapping can be performed manually by relating the boring tool position data collected by the PDU 28 to a base reference point, or may be performed electronically using a Geographic Recording System (GRS) 150 shown generally as a component of the control unit 32 in FIG. 24. In one embodiment, a Geographic Recording System (GRS) 150 communicates with a central processor 152 of the control unit 32 , relaying the precise location of the PDU 28 . Since the control unit 32 also receives information regarding the position of the boring tool 24 relative to the PDU 28 , the precise location of the boring tool 24 can be calculated and stored in a route recording database 154 .
[0133] In accordance with another embodiment, the geographic position data associated with a predetermined underground boring route is acquired prior to the boring operation. The predetermined route is calculated from a survey performed prior to the boring operation. The prior survey includes GPR sensing and geophysical data in order to estimate the type of ground through which the boring operation will take place, and to determine whether any other utilities or buried hazards are located on a proposed boring pathway. The result of the pre-bore survey is a predetermined route data set which is stored in a planned route database 156 . The predetermined route data set is uploaded from the planned route database 156 into the control unit 32 during the boring operation to provide autopilot-like directional control of the boring tool 24 as it cuts its underground path. In yet another embodiment, the position data acquired by the GRS 150 is preferably communicated to a route mapping database 158 which adds the boring pathway data to an existing database while the boring operation takes place. The route mapping database 158 covers a given boring site, such as a grid of city streets or a golf course under which various utility, communication, plumbing and other conduits may be buried. The data stored in the route mapping database 158 may be subsequently used to produce a survey map that accurately specifies the location and depth of various utility conduits buried in a specific site. The data stored in the route mapping database 158 also includes information on boring conditions, ground characteristics, and prior boring operation productivity, so that reference may be made by the operator to all prior boring operational data associated with a specific site.
[0134] An important feature of the novel system for locating the boring tool 24 concerns the acquisition and use of geophysical data along the boring path. A logically separate Geophysical Data Acquisition Unit 160 (GDAU), which may or may not be physically separate from the PDU 28 , may provide for independent geophysical surveying and analysis. The GDAU 160 preferably includes a number of geophysical instruments which provide a physical characterization of the geology for a particular boring site. A seismic mapping module 162 includes an electronic device consisting of multiple geophysical pressure sensors. A network of these sensors is arranged in a specific orientation with respect to the trenchless underground boring system 12 , with each sensor being situated so as to make direct contact with the ground. The network of sensors measures ground pressure waves produced by the boring tool 24 or some other acoustic source. Analysis of ground pressure waves received by the network of sensors provides a basis for determining the physical characteristics of the subsurface at the boring site and also for locating the boring tool 24 . These data are processed by the GDAU 160 prior to sending analyzed data to the central processor 152 .
[0135] A point load tester 164 may be employed to determine the geophysical characteristics of the subsurface at the boring site. The point load tester 164 employs a plurality of conical bits for the loading points which, in turn, are brought into contact with the ground to test the degree to which a particular subsurface can resist a calibrated level of loading. The data acquired by the point load tester 164 provide information corresponding to the geophysical mechanics of the soil under test. These data may also be transmitted to the GDAU 160 .
[0136] The GDAU 160 may also include a Schmidt hammer 166 which is a geophysical instrument that measures the rebound hardness characteristics of a sampled subsurface geology. Other geophysical instruments may also be employed to measure the relative energy absorption characteristics of a rock mass, abrasivity, rock volume, rock quality, and other physical characteristics that together provide information regarding the relative difficulty associated with boring through a given geology. The data acquired by the Schmidt hammer 166 are also stored in the GDAU 160 .
[0137] In the embodiment illustrated in FIG. 24, a Global Positioning System (GPS) 170 is employed to provide position data for the GRS 150 . In accordance with a U.S. Government project to deploy twenty-four communication satellites in three sets of orbits, termed the Global Positioning System (GPS), various signals transmitted from one or more GPS satellites may be used indirectly for purposes of determining positional displacement of a boring tool 24 relative to one or more known reference locations. It is generally understood that the U.S. Government GPS satellite system provides for a reserved, or protected, band and a civilian band. Generally, the protected band provides for high-precision positioning to a classified accuracy. The protected band, however, is generally reserved exclusively for military and other government purposes, and is modulated in such a manner as to render it virtually useless for civilian applications. The civilian band is modulated so as to significantly reduce the accuracy available, typically to the range of one hundred to three hundred feet.
[0138] The civilian GPS band, however, can be used indirectly in relatively high-accuracy applications by using one or more GPS signals in combination with one or more ground-based reference signal sources. By employing various known signal processing techniques, generally referred to as differential global positioning system (DGPS) signal processing techniques, positional accuracies on the order of centimeters are now achievable. As shown in FIG. 24, the GRS 150 uses the signal produced by at least one GPS satellite 172 in cooperation with signals produced by at least two base transponders 174 , although the use of one base transponder 174 may be satisfactory in some applications. Various known methods for exploiting DGPS signals using one or more base transponders 174 together with a GPS satellite 172 signal and a mobile GPS receiver 176 coupled to the control unit 32 may be employed to accurately resolve the boring tool 24 movement relative to the base transponder 174 reference locations using a GPS satellite signal source.
[0139] In another embodiment, a ground-based positioning system may be employed using a range radar system 180 . The range radar system 180 includes a plurality of base radio frequency (RF) transponders 182 and a mobile transponder 184 mounted on the PDU 28 . The base transponders 182 emit RF signals which are received by the mobile transponder 184 . The mobile transponder 184 includes a computer which calculates the range of the mobile transponder 184 relative to each of the base transponders 182 through various known radar techniques, and then calculates its position relative to all base transponders 182 . The position data set gathered by the range radar system 180 is transmitted to the GRS 150 for storing in route recording database 154 or the route mapping system 158 .
[0140] In yet another embodiment, an ultrasonic positioning system 190 may be employed together with base transponders 192 and a mobile transponder 194 coupled to the PDU 28 . The base transponder 192 emits signals having a known clock timebase which are received by the mobile transponder 194 . The mobile transponder 194 includes a computer which calculates the range of the mobile transponder 194 relative to each of the base transponders 192 by referencing the clock speed of the source ultrasonic waves. The computer of the mobile transponder 194 also calculates the position of the mobile transponder 194 relative to all of the base transponders 192 . It is to be understood that various other known ground-based and satellite-based positioning systems and techniques may be employed to accurately determine the path of the boring tool 24 along an underground path.
[0141] [0141]FIG. 25 illustrates an underground boring tool 24 performing a boring operation along an underground path at a boring site. An important advantage of the novel geographic positioning unit 150 , generally illustrated in FIG. 25, concerns the ability to accurately navigate the boring tool 24 along a predetermined boring route and to accurately map the underground boring path in a route mapping database 158 coupled to the control unit 32 . It may be desirable to perform an initial survey of the proposed boring site prior to commencement of the boring operation for the purpose of accurately determining a boring route which avoids difficulties, such as previously buried utilities or other obstacles, including rocks, as is discussed hereinbelow.
[0142] As the boring tool 24 progresses along the predetermined boring route, actual positioning data are collected by the geographic recording system 150 and stored in the route mapping database 158 . Any intentional deviation from the predetermined route stored in the planned path database 156 is accurately recorded in the route mapping database 158 . Unintentional deviations are corrected so as to maintain the boring tool 24 along the predetermined underground path. Upon completion of a boring operation, the data stored in the route mapping database 158 may be downloaded to a personal computer (not shown) to construct an “as is” underground map of the boring site. Accordingly, an accurate map of utility or other conduits installed along the boring route may be constructed from the route mapping data and subsequently referenced by those desiring to gain access to, or avoid, such buried conduits.
[0143] Still referring to FIG. 25, accurate mapping of the boring site may be accomplished using a global positioning system 170 , range radar system 180 or ultrasonic positioning system 190 as discussed previously with respect to FIG. 24. A mapping system having a GPS system 170 includes first and second base transponders 600 and 602 together with one or more GPS signals 606 and 608 received from GPS satellites 172 . A mobile transponder 610 , coupled to the control unit 32 , is provided for receiving the GPS satellite signal 606 and base transponder signals 612 and 614 respectively transmitted from the transponders 600 and 602 in order to locate the position of the control unit 32 . As previously discussed, a modified form of differential GPS positioning techniques may be employed to enhance positioning accuracy to the centimeter range. A second mobile transponder 616 , coupled to the PDU 28 , is provided for receiving the GPS satellite signal 608 and base transponder signals 618 and 620 respectively transmitted from the transponders 600 and 602 in order to locate the position of the PDU 28 .
[0144] In another embodiment, a ground-based range radar system 180 includes three base transponders 600 , 602 , and 604 and mobile transponders 610 and 616 coupled to the control unit 32 and PDU 28 , respectively. It is noted that a third ground-based transponder 604 may be provided as a backup transponder for a system employing GPS satellite signals 606 and 608 in cases where GPS satellite signal 606 and 608 transmission is temporarily terminated, either purposefully or unintentionally. Position is data for the control unit 32 are processed and stored by the GRS 150 using the three reference signals 612 , 614 , and 622 received from the ground-based transponders 600 , 602 , and 604 , respectively. Position data for the PDU 28 , obtained using the three reference signals 618 , 620 , and 624 received respectively from the ground-based transponders 600 , 602 , and 604 , are processed and stored by the local position locator 616 coupled to the PDU 28 and then sent to the control unit 32 via a data transmission link 34 . An embodiment employing an ultrasonic positioning system 190 would similarly employ three base transponders 600 , 602 , and 604 , together with mobile transponders 610 and 616 coupled to the control unit 32 and PDU 28 , respectively.
[0145] Referring now to FIG. 26, there is illustrated in flowchart form generalized steps associated with the pre-bore survey process for obtaining a pre-bore site map and determining the optimum route for the boring operation prior to commencing the boring operation. In brief, a pre-bore survey permits examination of the ground through which the boring operation will take place and a determination of an optimum route, an estimate of the productivity, and an estimate of the cost of the entire boring operation.
[0146] Initially, as shown in FIG. 26, a number of ground-based transponders are positioned at appropriate locations around the boring site at step 300 . The control unit 32 and the PDU 28 are then situated at locations L 0 and L 1 respectively at step 302 . The geographical recording system 150 is then initialized and calibrated at step 304 in order to locate the initial positions of the control unit 32 and PDU 28 . After successful initialization and calibration, the PDU 28 is moved along a proposed boring route, during which PDU data and geographical location data are acquired at steps 306 and 308 , respectively. The data gathered by the PDU 28 are preferably analyzed at steps 306 and 308 . The acquisition of data continues at step 312 until the expected end of the proposed boring route is reached, at which point data accumulation is halted, as indicated at step 314 .
[0147] The acquired data are then downloaded to the control unit 32 , which may be a personal computer, at step 316 . The control unit 32 , at step 318 , then calculates an optimum pre-determined path for the boring operation, and does so as to avoid obstacles and other structures. If it is judged that the pre-determined route is satisfactory, as is tested at step 320 , the route is then loaded into the planned path database 156 at step 322 , and the pre-bore survey process is halted at step 324 . If, however, it is determined that the planned route is unsatisfactory, as is tested at step 320 because, for example, the survey revealed that the boring tool 24 would hit a rock obstacle or that there were buried utilities which could be damaged during a subsequent boring operation, then the PDU 28 can be repositioned, at step 326 , at the beginning of the survey route and a new route surveyed by repeating steps 304 - 318 . After a satisfactory route has been established, the pre-bore survey process is halted at step 324 .
[0148] In another embodiment, the pre-bore survey process includes the collection of geological data along the survey path, concurrently with position location and PDU data collection. This collection activity is illustrated in FIG. 26 which shows an initialization and calibration step 328 for the geophysical data acquisition unit 160 (GDAU) taking place concurrently with the initialization and calibration of the geographical recording system 150 . The GDAU 160 gathers geological data at step 330 at the same time as the PDU 28 and position data are being acquired in steps 306 and 308 , respectively. The inclusion of geological data gathering provides for a more complete characterization of the ground medium in the proposed boring pathway, thus allowing for more accurate productivity and cost estimates to be made for the boring operation.
[0149] In a third embodiment, the survey data are compared with previously acquired data stored in the route mapping database 158 in order to provide estimates of the boring operation productivity and cost. In this embodiment, historical data from the route mapping database are loaded into the control processor 152 at step 332 after the survey data have been downloaded to the control unit 32 in step 316 . The data downloaded from the route mapping database 158 include records of prior surveys and boring operations, such as GPR and geological characterization measurements and associated productivity data. The pre-planned route is calculated at step 334 in a manner similar to the calculation of the route indicated at step 318 . By correlating the current ground characterization, resulting from the PDU 28 and GDAU 160 data, with prior characterization measurements and making reference to associated prior productivity results, it is possible to estimate, at step 336 , productivity data for the planned boring operation. Using the estimated production data of step 336 , it is then possible to produce a cost estimate of the boring process at step 338 . In the following step 320 , a determination is made regarding whether or not the pre-planned route is satisfactory. This determination can be made using not only the subsurface features as in the first embodiment, but can be made using other criteria, such as the estimated duration of the boring process or the estimated cost.
[0150] Referring now to FIG. 27, there is illustrated a system block diagram of a control unit 32 , its various components, and the functional relationship between the control unit 32 and various other elements of the trenchless underground boring system 12 . The control unit 32 includes a central processor 152 which accepts input data from the geographic recording system 150 , the PDU 28 , and the GDAU 160 . The central processor 152 calculates the position of the boring tool 24 from the input data. The control processor 152 records the path taken by the boring tool 24 in the route recording database 154 and/or adds it to the existing data in the route mapping database 158 .
[0151] In an alternative embodiment, the central processor 152 also receives input data from the sensors 230 located at the boring tool 24 through the sensor input processor 232 . In another embodiment, the central processor 152 loads data corresponding to a predetermined path from the planned path database 156 and compares the measured boring tool position with the planned position. The position of the boring tool 24 is calculated by the central processor 152 from data supplied by the PDU input processor 234 which accepts the data received from the PDU 28 . In an alternative embodiment, the central processor 152 also employs data on the position of the PDU 28 , supplied by the Geographic Recording System 150 , in order to produce a more accurate estimate of the boring tool location.
[0152] Corrections in the path of the boring tool 24 during a boring operation can be calculated and implemented to return the boring tool 24 to a predetermined position or path. The central processor 152 controls various aspects of the boring tool operation by use of a trenchless ground boring system control (GBSC) 236 . The GBSC 236 sends control signals to boring control units which control the movement of the boring tool 24 . These boring control units include the rotation control 238 , which controls the rotating motor 19 for rotating the drill string 22 , the thrust/pullback control 242 , which controls the thrust/pullback pump 20 used to drive the drill string 22 longitudinally into the borehole, and the direction control 246 , which controls the direction activator mechanism 248 which steers the boring tool 24 in a desired direction. The PDU input processor 234 may also identify buried features, such as utilities, from data produced by the PDU 28 . The central processor 152 calculates a path for the boring tool 24 which avoids any possibility of a collision with, and subsequent damage to, such buried features.
[0153] In FIGS. 28 and 29, there are illustrated flow charts for generalized process and decision steps associated with boring a trenchless hole through the ground. Initially, as shown in FIG. 28 and at step 350 , a number of ground-based transponders are positioned at appropriate locations around a boring site. The trenchless underground boring system 12 is then positioned at the appropriate initial location, as indicated at step 352 , and the transponders and geographic recording system are initialized and calibrated, at step 354 , prior to the commencement of boring, at step 356 . After boring has started, the PDU 28 probes the ground at step 358 and then receives and analyzes the signature signal at step 360 . Independent of, and occurring concurrently with, the probing and receiving steps 358 and 360 , the GRS receives position data at step 362 and determines the position of the PDU 28 at step 364 . After steps 362 and 364 have been completed, the central processor 152 then determines the position of the boring tool 24 at step 366 .
[0154] The central processor 152 then compares the measured position of the boring tool 24 with the expected position, at step 368 , as given in the planned path database 156 and calculates whether or not a correction is required to the boring tool direction, at step 370 , and provides a correction at step 372 , if necessary. The trenchless underground boring system 12 continues to bore through the ground at step 374 until the boring operation is completed as indicated at steps 376 and 378 . If, however, the boring operation is not complete, the central processor 152 decides, at step 380 , whether or not the PDU 28 should be moved in order to improve the image of the boring tool 24 . The PDU 28 is then moved if necessary at step 382 and the probing and GRS data reception steps 358 and 362 recommence. The operation is halted after the boring tool 24 has reached a final destination.
[0155] In an alternative embodiment, shown in dashed lines in FIGS. 28 and 29, the central processor 152 records, at step 384 , the calculated position of the boring tool 24 in the route mapping database 158 and/or the route recording database 154 , after determining the position of the boring tool at step 366 . In another embodiment, the steps of comparing (step 368 ) the position of the boring tool 24 with a pre-planned position and generating any necessary corrections (steps 370 and 372 ) are omitted as is illustrated by the dashed line 386 .
[0156] It will, of course, be understood that various modifications and additions can be made to the preferred embodiments discussed hereinabove without departing from the scope or spirit of the present invention. Accordingly, the scope of the present invention should not be limited by the particular embodiments described above, but should be defined only by the claims set forth below and equivalents thereof.
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An apparatus and method for horizontally drilling provides for detecting subsurface features and avoiding such features during closed-loop control of an underground drilling machine. A horizontal drilling system includes a base machine capable of propelling a drill pipe rotationally and longitudinally underground. A cutting tool system is coupled to the drill pipe, and a control system controls the base machine. A detector is employed to detect a subsurface feature. A communication link is utilized for transferring data between the detector and the control system. The control system uses the data generated by the detector to modify control of the base machine in response to detection of the subsurface feature.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/781,267 filed Feb. 17, 2004, which is a continuation of U.S. patent application Ser. No. 10/177,920, now U.S. Pat. No. 6,691,483, filed Jun. 21, 2002, both of which are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to panel doors, and more particularly to panel pet doors for insertion into sliding glass doors.
Panel pet doors for sliding glass doors are pet doors designed to fit in the space that results when a sliding glass door is partially opened (or, also, the resulting space when a stationary panel is moved to one side). The advantage to this type of pet door is that it does not require cutting a hole through, and thereby ruining, a door.
There are three dimensions that are critical to accommodating the animal(s) that will be using a panel pet door: width of a flap opening, height of the flap opening and, just as important, rise. The rise is defined as the height of a bottom edge of the flap above a base of the panel door. For a most comfortable fit, the top edge of the flap should be about the same height as the pet at the top of the withers (top of the shoulder). Customarily, panel pet door flaps have not been designed to be that height. Rather, the flap is raised up off the ground (the rise) so as to get the flap opening about even with the trunk of the pet's body. Short dogs would prefer a shorter rise and taller dogs need a higher rise. For example, currently a pet door company manufactures a “large” pet door with a flap that measures 10×15 inches with a 5 inch rise. They also offer a “large/tall” pet door using the same flap, but with a 9 inch rise.
It would be beneficial to a consumer to offer the largest sizes in at least three or four different rises and for medium and small/medium sizes to be offered in at least two rises. It would also be beneficial to offer customers ways to change the size of the flap door and/or rise, such as when a dog changes size over time, e.g., grows from a puppy into a mature dog. Heretofore, the only way a manufacturer could offer multiple rise options was by building and maintaining an inventory of separate panel pet door sizes for each rise option.
It would also be beneficial to offer customers ways to change the size of the flap door in addition to adjusting the height of the rise, all without replacing the entire panel pet door. Common circumstances which would make this desirable occur when, for example, the owner of a taller dog acquires a short dog (desiring to preserve the height of the present flap, but shorten the rise.), or vice versa. Also, if an owner's dog becomes injured the dog may benefit from a lower rise and/or a taller flap.
There is thus a need in the art for a panel pet door that provides a way to offer customers different height and rise combinations of the pet door flap without having to manufacture a separate panel pet door for each combination, and provides a way for customers to adjust the rise and height of the pet door flap without having to replace an entire panel pet door.
SUMMARY OF THE INVENTION
The present invention advantageously addresses the needs above as well as other needs by providing a panel door and method of adjusting the panel door.
In one embodiment, the invention can be characterized as a panel door assembly comprising a panel door frame, an entrance portal assembly mounted on the panel door frame that is vertically slidable on the panel door frame and a spacer panel mounted on the panel door frame that is vertically slidable on the frame.
In another embodiment, the invention can be characterized as a the panel door assembly described above further comprising at least one additional spacer panel mounted on the panel door frame that is vertically slidable on the panel door frame, a total number of spacer panels mounted on the panel door frame comprising a plurality of vertically slidable spacer panels.
In another embodiment, the invention can be characterized as a method of adjusting an entrance of a panel door assembly comprising the steps of sliding vertically at least one spacer panel and an entrance portal assembly out of a panel door frame of the panel door assembly and sliding vertically at least one spacer panel and the entrance portal assembly into the panel door frame in a configuration such that the entrance portal is at a different height from a bottom of the panel door frame.
In another embodiment, the invention can be characterized as a method of adjusting an entrance of a panel door assembly comprising the steps of sliding vertically at least one spacer panel and a first entrance portal assembly out of a panel door frame of the panel door assembly and sliding vertically a second entrance portal assembly of a different height than the first into the panel door frame.
In yet another embodiment, the invention can be characterized as a method of adjusting an entrance of a panel door assembly comprising the steps of sliding vertically a first entrance portal assembly out of a panel door frame of the panel door assembly and sliding vertically a second entrance portal assembly of a different height than the first and at least one spacer panel into the panel door frame.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description of the invention and accompanying drawings which set forth an illustrative embodiment in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1 is a front elevation view of a fixed rise/height panel pet door;
FIG. 2 is a front elevation view of another fixed rise/height panel pet door;
FIG. 3 is a front elevation view of a panel pet door according to an embodiment of the present invention;
FIG. 4 is a partial top cross sectional view of the panel pet door of FIG. 3 ;
FIG. 5 is a partial top cross sectional view of an alternative embodiment of the panel pet door of FIG. 3 ;
FIG. 6 is a partial top cross sectional view of a further alternative embodiment of the panel pet door of FIG. 3 ;
FIG. 7 is a front perspective view of the entrance portal assembly according the embodiment of the present invention shown in FIG. 3 ;
FIG. 8 is a front perspective view of a stepwise assembly of an alternative embodiment of an entrance portal assembly according to the present invention.
FIG. 9 is a side cross sectional view of a spacer panel according to an embodiment of the present invention;
FIG. 10 is a side cross sectional view of taller spacer panel than that of FIG. 9 according to an embodiment of the present invention;
FIG. 11 is a side cross sectional view of an alternative embodiment of a spacer panel according to the present invention;
FIG. 12 is a front perspective view of the panel pet door of FIG. 3 according to the present invention, using a different number, size and configuration of spacer panels;
FIG. 13 is a partial side cross sectional view of the panel pet door of FIG. 12 ;
FIG. 14 is a close-up partial side cross sectional view of the panel pet door of FIG. 12 ;
FIG. 15 is a front elevation view of the panel pet door of FIG. 3 installed in a sliding glass door frame;
FIG. 16 is a front perspective view of the-panel pet door of FIG. 15 installed in a sliding glass door frame; and
FIG. 17 is a side cross sectional view of the panel pet door in a sliding door of FIG. 16 .
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the presently contemplated best mode of practicing the invention is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
Referring to FIGS. 1 and 2 , shown are front elevation views of examples of panel pet doors with fixed, i.e., single, rise and height dimensions. In FIG. 1 , a fixed door flap 100 has a rise equal to the height of a cross member 105 . To make the rise higher, a separate panel door ( FIG. 2 ) is built with the door flap 200 raised higher and a first additional fixed cross piece 210 attached permanently below a second additional cross piece 215 below the door flap 200 and above cross member 205 . One difficulty with this approach is that it results in a great many stocking units (SKU's), i.e., a great deal of panel pet door inventory, and an increase in raw materials inventory to support manufacturing. Also, production efficiency is decreased as there are many small production runs for each of a large number of rise options for each flap size. For example, in the event a panel pet door is available in four standard height adjustment ranges, three frame colors and, counting each size/rise combination as separate, 16 size/rise combinations, a total of 192 SKU's are required, i.e., a total of 192 different panel pet door models must be maintained in inventory.
Referring to FIGS. 3 and 4 , shown in FIG. 3 is a front elevation view of a panel pet door 300 according to an embodiment of the present invention and in FIG. 4 shown is a partial top cross sectional view of the panel pet door of FIG. 3 . Shown in FIG. 3 are the panel door frame 301 having two vertical stiles 302 , 303 , and a top horizontal frame cross piece 304 . Also shown are a glass pane 305 , a top fixed cross piece 310 a movable top spacer panel 315 , a movable entrance portal assembly 316 (having a movable frame 320 and a door flap 325 ), two movable riser spacer panels 330 , 335 , and a bottom fixed cross piece 340 . In FIG. 4 shown is the movable top spacer panel 315 and stile 302 of FIG. 3 along with a vertical track 400 in the stile 302 .
The panel door frame 301 is a solid frame of wood, metal, plastic or vinyl (preferably metal). The two stiles 302 , 303 are fixedly attached to the top horizontal frame cross piece 304 and may be formed integral with the two vertical stiles 302 , 303 . A pane 305 (preferably of glass) is attached in the interior of the top portion of the frame 301 above the top fixed cross piece 310 that extends horizontally between the two stiles 302 , 303 .
Directly below the top fixed cross piece 310 is the movable top spacer panel 315 . This panel 315 fits into and is movable vertically along a vertical track 400 in each stile 302 , 303 (shown in FIG. 4 ) located on the interior of the two stiles 302 , 303 . The top spacer panel 315 is located above and rests on the movable entrance portal assembly 316 (preferably a movable door flap assembly 316 ). The movable door flap assembly 315 is also movable along vertical tracks 400 (shown in FIG. 4 ) located on the interior of the two stiles 302 , 303 .
The door flap assembly 316 has a movable frame 320 that fits into the tracks 400 of the stiles 302 , 303 (shown in FIG. 4 ) like the movable top spacer panel 315 .
Preferably, two vertical frame members 321 , 322 of the movable frame 320 fit into the tracks 400 of the stiles 302 , 303 (as in FIG. 4 ). The door flap 325 is preferably flexible and is hingedly attached to the movable frame 320 to allow the passage of pets through the flap 325 .
Located below the door flap assembly 316 in the panel door frame 301 are two movable riser spacer panels 330 , 335 that are also movable along the tracks 400 of the two stiles 302 , 303 (shown in FIG. 4 ). Located below the two riser spacer panels is the bottom fixed cross piece 340 . The bottom fixed cross piece is fixedly attached between the bottom of the two stiles 302 , 303 , and is preferably removable and thus not formed integral with the panel door frame 303 .
The spacer panels 315 , 330 , 335 and the door flap assembly 316 can be slid out of the panel door frame 301 through an opening in the bottom of the frame 301 by removal of the bottom fixed cross piece 340 from the panel door frame 301 . This is to allow removal and replacement of the spacer panels 315 , 330 , 335 and the door flap assembly 316 . Replacement of the spacer panels 315 , 330 , 335 into the panel door frame 301 in a different configuration and/or with spacer panels of a different size effects a change in the rise (the distance between the bottom of the door flap 325 and bottom of the panel door 300 ). For example, to increase the rise to a degree equal to the height of the top spacer panel 315 , first remove the bottom cross piece 340 and then remove spacer panels 315 , 330 , 335 and the door flap assembly 316 by sliding them out through the bottom of the panel door frame 301 . Next, slide in the door flap assembly 316 into the panel door frame and then slide the same spacer panels 315 , 330 , 335 below the door flap assembly 316 into the panel door frame 301 . Finally, replace the bottom fixed cross piece by reattaching it between the bottom of the two stiles 302 , 303 . Now all the spacer panels 315 , 330 , 335 are located below the door flap assembly 316 , thus increasing the rise of the door flap 325 .
A removable bottom crosspiece 340 may be attached to the stiles 302 , 303 by reusable means such as screws or a locking mechanism (preferably screws). Also, replacement of the spacer panels 315 , 330 , 335 with a spacer panel (or panels) of a different height or heights can also effect a change in the rise. The height of the door flap assembly 316 in the panel door 300 may also be changed by sliding out the door flap assembly 316 in the manner previously described and replacing it with a door flap assembly of a different height. Optionally, this may be done in combination with changing the rise as described above.
It is important to note that the area between the top fixed cross piece 310 and the bottom fixed cross piece 340 may be filled with a door flap assembly 316 of any selected height and any combination of spacer panels of various optional heights, either above or below the door flap assembly 316 .
Referring next to FIG. 5 , shown is a partial top cross sectional view of an alternative embodiment of the panel pet door of FIG. 3 . Shown is the stile 302 of FIG. 4 having a vertical track 400 and an alternative embodiment of the movable top spacer panel 315 having a vertical track 500 in the spacer 315 .
The vertical track 500 is located on each side of the spacer 315 (one side shown in FIG. 5 ) and is representative of an alternative way for spacers and door flap assemblies to fit in the panel door frame 301 . The track 500 is slightly wider than the depth of the stile 302 such that the stile 302 fits into the vertical track 500 and allows the spacer 315 to slide vertically along the stile 302 .
Referring next to FIG. 6 , shown is a partial top cross sectional view of an alternative embodiment of the panel pet door of FIG. 3 . Shown is the stile 302 of FIG. 4 having a vertical track 4 . 00 and an alternative embodiment of the movable top spacer panel 315 having a vertical tracks 610 , 615 in the spacer 315 .
The vertical tracks 600 , 605 are located on each side of the spacer 315 (one side shown in FIG. 6 ) and is representative of an alternative way for spacers and door flap assemblies to fit in the panel door frame 301 . The tracks 600 , 605 are slightly wider than the depth of walls 610 , 615 of the track 400 in the stile 302 . Thus, the track walls 610 , 615 fit respectively into the vertical tracks 600 , 605 of the spacer 315 and allow the spacer 315 to slide vertically along the stile 302 .
Referring next to FIG. 7 , shown is a front perspective view of the entrance portal assembly 316 (a door flap assembly in this case) according to the embodiment of the present invention shown in FIG. 3 . Shown are the door flap frame 320 , the two vertical frame members 321 , 322 of the door flap frame 320 and the door flap 325 .
The door flap assembly frame 320 has guides 323 , 324 on the exterior of the vertical frame members that fit into the vertical stiles 302 , 303 (shown in FIG. 3 ) of the panel door frame 302 that allow the door flap assembly 316 to slide vertically along the panel door frame 301 as a single unit. Located on the top and bottom of the door flap frame are projections 326 , 327 that allow the door flap assembly 316 to nest into the bottom and top of spacer panels 315 , 330 , respectively (shown in FIG. 3 ).
Referring next to FIG. 8 , shown is a front perspective view of a stepwise assembly of an alternative embodiment of an entrance portal assembly 1000 according to the present invention. Shown is a door flap frame 1002 and a standard (wall or door mounted) pet door 1005 with a flap 1010 . The flap frame 1002 is a carrier onto which the pet door 1005 is mounted. The perimeter of the completed door flap assembly 1000 fits into the panel door frame 301 and spacer panels 315 , 330 (shown in FIG. 3 ) in the same manner as the door flap assembly 316 of FIG. 7
Referring next to FIGS. 9 , 10 and 11 , shown are side cross sectional views of a spacer panel, a taller spacer panel and an alternative embodiment of a spacer panel according to the present invention, respectively.
FIGS. 9 and 10 show spacer panels 916 , 920 having vertical protrusions 930 at the top and bottom of the panels 916 , 920 that allow nesting of the panels 916 , 920 . The protrusions 930 at the bottom of the panels 916 , 920 fit over the protrusions 930 at the top of the panels below them. The protrusions 930 are sufficiently long to allow clearance 940 for screw heads, other fastening means, and weather stripping to fit between the panels 916 , 920 . The spacer 920 of FIG. 10 is taller to replace two or more “single size” spacers. The spacer 925 of FIG. 11 has a protrusion 935 on top of the spacer with a cross member to shed water more efficiently, but leaves no gap for screw heads.
Referring next to FIG. 12 , shown is a front perspective view of the panel pet door 300 of FIG. 3 according to the present invention, using a different number, size and configuration of spacer panels.
Shown in FIG. 12 is the panel door frame 301 having two vertical stiles 302 , 303 , and a top horizontal frame cross piece 304 . Also shown are a glass pane 305 , a top fixed cross piece 310 nested movable spacer panels 945 , a movable entrance portal assembly 316 , and a bottom fixed cross piece 340 . Note in FIG. 12 that in this configuration the spacer panels 945 are all above the entrance portal assembly 316 , thus lowering the rise of the entrance portal assembly.
Referring next to FIG. 13 , shown is a partial side cross sectional view of the panel pet door 300 of FIG. 12 . Shown in FIG. 13 is the top fixed cross piece 310 nested movable spacer panels 945 , the movable entrance portal assembly 316 (showing the door flap assembly frame 320 and flap 325 ), and a bottom fixed cross piece 340 .
Note how the spacers 945 nest together, one on top of the other, and also into the bottom of the top fixed cross piece 310 . Also, the door flap assembly frame 320 nests into the spacers panels 945 above it and into the bottom fixed cross piece below it.
Referring next to FIG. 14 , shown is a close-up partial side cross sectional view of the panel pet door 300 of FIG. 12 . Shown in FIG. 13 is the top fixed cross piece 310 , nested movable spacer panels 945 and the top part of the movable entrance portal assembly 316 (showing the top of the door flap assembly frame 320 and flap 325 ). Shown in detail are the protrusions 930 on the top and bottom of the spacers 945 that nest together 950 . Also note the clearance 940 between the spacer panels 945 for weather stripping, screws and other hardware.
Referring next to FIGS. 15 and 16 , shown are front elevation and front perspective views, respectively, of the panel pet door 300 of FIG. 3 installed in a sliding glass door 700 . Shown in FIGS. 15 and 16 are the panel door 300 and sliding glass door 700 , a sliding glass door frame 705 , a top horizontal frame member 715 , a bottom horizontal frame member 710 and a glass door 720 . Shown in FIG. 16 are horizontal tracks 800 , 805 of the sliding glass door frame 705 .
The panel pet door 300 fits as an insert into the frame 705 of the sliding glass door 700 . The panel door frame 301 is of sufficient height to fit inside the sliding glass door frame 705 onto the respective tracks 800 , 805 of the top and bottom frame members 715 , 710 , of the sliding glass door frame 705 (as shown in detail in FIG. 17 ).
Referring next to FIG. 17 , is a side cross sectional view of the panel pet door 300 in the sliding door 700 of FIG. 16 . Shown is the vertical stile 302 and top and bottom cross pieces 304 , 340 of the panel door frame 301 of the panel door 300 . Also shown are the top and bottom tracks 800 , 805 of the sliding glass door frame 705 , a spring mechanism 900 having a spring 905 and a rail 901 , and a thumb screw 910 .
The spring mechanism 900 is located on the top of the top horizontal frame cross piece 304 of the panel door frame 301 . The spring 905 supports the rail 901 which is inserted into top track 800 of the sliding glass door 700 . The thumb screw is located on the interior side of the panel door frame 301 and is operably connected to the spring mechanism such that the spring mechanism is locked in place when the thumb screw is tightened and unlocked when loosened. The bottom cross piece 340 of the panel door frame 301 has a horizontal channel 915 that allows the bottom cross piece 340 to fit into the bottom outside track 805 of the sliding glass door frame 705 .
The panel pet door frame 301 is inserted into the sliding glass door frame 705 by first loosening the thumb screw 910 , then inserting the spring mechanism 900 into the top track 800 . Then, while pushing up against the spring mechanism 900 , the bottom of the panel door frame 301 is swung onto the bottom rail 805 . The thumb screw 910 is then tightened to lock the spring mechanism 900 and thus the panel door frame 301 in place.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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An adjustable panel door comprises a panel door frame having a top cross piece and a bottom cross piece. A portal assembly provides access through the panel door. The portal assembly is positioned between the top cross piece and the bottom top piece. At least one spacer panel is adjustably positioned on the panel door frame adjacent to the portal assembly. The position of the portal assembly is adjustable by altering a position of the at least one spacer panel along the panel door frame.
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Prunus persica.
BACKGROUND OF THE NEW VARIETY
The present invention relates to a new and distinct variety of peach tree ( Prunus persica ) which will hereinafter be denominated varietally as the ‘JR 7827’ peach and more particularly as a peach tree which produces free stone fruit which can mature for commercial harvest between approximately June 15-25 of each year.
The present invention is a bud sport of a ‘Saucer’ peach (nonpatented) that was discovered in a ‘Saucer’ peach planting in the Goshen area of the San Joaquin Valley of Central California in the year 2000. This new variety has the appearance of a ‘Saucer’ peach as far as the fruit shape (saucer), however it is very highly colored and is yellow fleshed. This bud sport was grafted on a ‘Nemaguard’ rootstock and planted on the property of the inventor in 2002. By the third year, 2005, the tree had produced a very good crop. The inventor examined the progeny and found that it possessed all the characteristics of the parent.
ORIGIN AND ASEXUAL REPRODUCTION OF THE NEW VARIETY
The present invention (variety) was discovered in a ‘Saucer’ peach planting at Road 52 and Avenue 320, west of the town of Goshen, Calif. in the year 2000. The new variety was asexually reproduced by bud grafting on ‘Nemaguard’ rootstock in 2002 on one tree at 3031 South Oak Park Street, Visalia, Calif. 93177. The inventor carefully compared the asexually reproduced tree with the parent sport including the fruit and found they were identical in all respects. The tree described herein is a three year old tree.
SUMMARY OF THE NEW VARIETY
The ‘JR 7827’ peach is characterized by producing a saucer shaped peach with good blush coloration and is ripe for commercial harvesting and shipment around June 15-June 25 in a normal year in the San Joaquin Valley of Central California as a yellow fleshed, saucer shaped fruit. The new variety of peach is most similar to the ‘Saucer’ peach (nonpatented) from which it is a bud sport and from which it is distinguishable in that it is more highly colored, has yellow flesh and excellent flavor. The maturity date is at about the same time as the ‘Saucer’ peach. With good color and excellent flavor, this fruit is markedly quite acceptable to the consumer.
BRIEF DESCRIPTION OF THE DRAWING
The drawing ( FIG. 1 ) is a color photograph of the new variety of peach tree displaying the foliage along the left side and the fruit along the right side. The foliage at the top of the photograph is from a terminal branch, the underside of a leaf is shown in the middle of the photograph next to two fruit pits, and the foliage at the bottom is from an older branch. Along the right side of the photograph, starting at the top, is a top view of a mature fruit, followed by a bottom view of a mature fruit, followed by two suture (side) views of the fruit, followed by a half section of a fruit displaying flesh color and pit well, and ending with the other half section of the fruit displaying the flesh and the pit in the pit well.
DETAILED DESCRIPTION
Referring more specifically to the horticultural details of the new and distinct variety of peach tree, the following description has been observed under the ecological conditions prevailing at the origin location which is in the City of Visalia in the San Joaquin Valley of Central California. All major color designations are by reference to the Dictionary of Color by Maera & Paul, First Edition, published in 1930. Common colors are also employed.
TREE
Size—medium—10-11 feet high, 8-9 feet wide.
Vigor—very good at third leaf, with 6-12 inches of new growth.
Chilling requirements—normal for peaches in the San Joaquin Valley of Central California (approx. 800 hours below 45° F.).
Productivity—very good for third leaf tree (comparable to that of fourth leaf trees of other peach varieties).
Regularity of bearing—regular.
Figure—pyramidal—upright and spreading.
Trunk:
Size. —Medium — 9 inches in circumference at 12 inches above soil level. Surface texture. —Rough. Color code. —Catawba (56-J-10). Lenticels. —Number—many scattered, 20-25 over a 3-inch square bark surface. Size—11-12 mm (0.43-0.47 inch) on trunk 1 mm (0.04 inch) on branches. Color—(55-H-3) light brown.
Branches:
Size. —Medium — 6 inches in circumference at 10 inches above crotch. Length. —Typically 4-5 feet. Angle of scaffold branches above the crotch. —Approximately 63°. Surface texture. —Mature branches—fairly smooth. Immature branches—smooth. Color code.— 1 year or older—Pigeon (55-A-3). Immature—Piquant gr. (20-K-6). Lenticels. —Many, small 1 mm (0.04 inch).
Leaves:
Size. —Medium, pinnately veined. Length: 125-132 mm (4.87-5.15 inch). Width: 38-44 mm (1.48-1.72 inch). Form. —Lanceolate. Base. —Cuneate. Tip. —Acuminate. Color code. —Upwardly disposed surface—Empire gr. (23-E-9). Downwardly disposed surface—Near garland gr. (22-H-7). Marginal form. —Serrated. Leaf vein. —Color Code—Fern (21-I-4). Thickness—1 mm (0.04 inch). Petiole. —Size: Length—11-12 mm (0.43-0.47 inch). Thickness—1-2 mm (0.04-0.08 inch). Color Code—Fern (21-I-7). Stem Glands: 0-1 reniform. Color Code—Taupe (16-A-6). Glands. —Size—small—1 mm (0.04 inch). Form—reniform, one on each side of petiole. Color—(20-B-2) Artichoke Gr. Stipules. —Size—one double and one single, 1-2 mm (0.04-0.08 inch). Color Code—tips—Partridge (15-L-2).
FLOWERS
Flower buds:
Size. —Length—8-9 mm (0.31-0.35 inch). Width—7-8 mm (0.27-0.31 inch). Height—3 mm (0.12 inch).
Form: conic.
Color code. —Vineyard Oporto+ (55-L-12) at base.
Flower:
Calyx.— 5 sepals with some pubescence on margins and edge. Color Code: Vineyard Oporto+ (55-L-12) at base, Reddish gray (54-F-4). Date of bloom. —February 28: 10-15%. March 6: 95%. Size. —Large when fully opened. Diameter—51-53 mm (1.99-2.07 inches). Quantity. —Abundant, mostly two in a cluster. Fragrance. —None. Petals.— 5. Size—generally large. Length—20-23 mm (0.78-0.90 inch). Width—15-17 mm (0.59-0.66 inch). Form—broadly ovate with slightly undulate margins. Color—Peach Blossom (1-C-2) at tip to Spinel R. (3-H-5) on lower half of petal. Apex—rounded. Margin—undulate. Base—tapered. Claws—small—2 mm (0.079 inch) width. Color Code—Jack Rose (3-J-6). Pedicels. —Length—3 mm (0.12 inch). Width—1.5 mm (0.06 inch). Color—midvein: GARNET+ Spanish Wine, Pigeon Blood− (7-J-6). Sepals.— 5. Observed shape—narrowly triangular. Margin—entire. Apex—acuminate. Outside surface Color Code—Vineyard Oporto+ (55-L-12). Length—6-7 mm (0.23-0.27 inch). Width—4-5 mm (0.16-0.20 inch). Stamens.— 38-40. Length—12-19 mm (0.47-0.74 inch). Filaments. —Color Code—from white (1-B-1) to pink (1-F-2). Anthers. —Color code—Chutney (7-I-12). Pistil. —Length—12 mm (0.47 inch). Color code—Javel gr. (19-L-2). Ovary. —Color Code—Cosse gr. (19-L-6).
Maturity—June 15-25.
Size: Small to medium.
Diameter in axial plane.— 40 mm (1.56 inches). Transverse in suture plane.— 70 mm (2.73 inches). Transverse at right angles to suture plane.— 68 mm (2.65 inches).
Form:
Uniform. —Not uniform. Symmetrical or not symmetrical. —Symmetric — saucer shape. Suture. —Faint. Ventral surface. —Smooth. Stem cavity. —Width—12 mm (0.47 inch). Length—2.5 mm (0.10 inch). Depth—10 mm (0.39 inch). Form—ovate. Stem length. —Short — 5 mm (0.20 inch). Stem color. —(20-J-4) near Absinthe Gr. Apex. —None. Pistil point. —None. Caliper.— 4 mm (0.16 inch).
Skin:
Thickness. —Thin. Texture. —Firm. Tendency to crack. —Not known. Color code. —Blush—Pansy Pr. (54-L-8). Ground Color—March Rose (5-I-9). Flesh Color—Apricot Y (9-K-5) and on one side of flesh Off White (3-A-7). Surface of Pit Cavity—Apricot Y (9-K-5). Pit Well—Raspberry (6-I-5).
Flesh:
Juice production. —Very good. Flavor. —Very good. Aroma. —Moderate. Texture. —Slightly firm to soft. Fibers. —Few. Ripening. —Even. Eating quality. —Very good to excellent.
Use—fresh market.
Keeping & shipping quality—short term.
Resistance to disease—not known.
Harvesting—June 15-25.
STONE
Free or cling—Free.
Fibers:
Numbers. —Numerous. Length.— 10-13 mm (0.39-0.51 inch).
Size:
Length.— 11-14 mm (0.43-0.55 inch). Width.— 17-23 mm (0.57-0.91 inch). Thickness.— 12-14 mm (0.47-0.55 inch).
Form—oval — flat to slightly rounded at both apex and base.
Apex shape—flat to slightly rounded.
Color dry—Wild Cherry (6-C-6).
Base—flat to slightly rounded.
Sides—even but heavily pitted.
Hilium—3-5 mm (0.12-0.195 inch).
Ridges—on ventral side narrower than on distal side, from base to apex.
Tendency to split—none observed.
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A new and distinct variety that is characterized by producing a freestone fruit with good coloration and that is ripe for commercial harvesting and shipment June 15-25 in the San Joaquin Valley of Central California. The new variety is closely similar to the ‘Saucer’ peach tree (non-patented) from which it is a bud sport and from which it is distinguishable in that the fruit is much more highly colored, and has yellow flesh.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
The present invention relates to guided transport of containers between adjacent locations, such as land-based trucks and dockside moored sea vessels.
BACKGROUND OF THE INVENTION
Current methods and apparatus for transport of containers between ships at port and land-based dockside locations involve use of typical marine terminal cranes having a single rail guided trolleys on a boom extending between such container receiving and delivery locations. Such container transport cranes have facilities involving factors which limit transport rapidity and efficiency with respect to containers. It is therefore an important object of the present invention to provide for more efficient container crane loading and unloading of sea vessels to avoid port traffic delays.
SUMMARY OF THE INVENTION
Pursuant to the present invention, containers are loaded onto and removed from two trolleys of a single crane to double the rate of container transfer. Such trolleys are respectively guided along upper and lower travel paths vertically spaced from each other along a horizontal crane boom suspended by cables anchored to the upper end of the crane support frame that is positioned by motorized wheel assemblies between container receiving and delivery locations on a land-based surface. Each of such travel paths is established by a pair of rails laterally spaced from each other on the boom positioned so as to extend between the container receiving and delivery locations, at which such as a land-based truck vehicle and a dockside shipping sea vessel are positioned. The vertical spacing between travel paths and the lateral spacing between the boom rails accommodate handling of many containers to be loaded and unloaded without obstruction or delay in transport.
BRIEF DESCRIPTION OF DRAWING
A more complete appreciation of the invention and many of its attendant advantages will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:
FIG. 1 is a perspective view of a container transport crane constructed in accordance with one embodiment of the present invention;
FIG. 2 is an end view of the crane shown in FIG. 1 , as viewed from a container receiving or delivery location;
FIG. 3 is top plan view of the crane shown in FIG. 1 ;
FIG. 4 is a side elevation view of the crane illustrated in FIGS. 1-3 , positioned between typical container receiving and delivery locations;
FIGS. 5 and 6 are partial sections views respectively taken substantially through section lines 5 — 5 and 6 — 6 in FIG. 3 ; and
FIG. 7 is a partial section view substantially taken through section line 7 — 7 in FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing in detail, FIGS. 1 , 2 and 3 illustrate a container transfer crane generally referred to by reference numeral 10 . Such crane 10 includes a vertical support frame 12 to which a horizontal boom 14 is connected by pairs of cables 16 a and 16 b. Such cables 16 are fixedly anchored to an upper rectangular end portion 18 of the support frame 12 , having four vertical gantry legs 20 extending downwardly therefrom. The boom 14 includes a pair of rails 22 interconnected in laterally spaced relation to each other at their forward and rear ends by end connectors 24 and 26 . The frame anchored cables 16 a and 16 b are connected to the rails 22 adjacent to their forward and rear ends so that the boom 14 is supported in a horizontal position extending through the upper end portion of the support frame 12 in contact with the gantry legs 20 .
The crane 10 is moved to a position on a land-based surface as shown in FIG. 4 by motorized wheel assemblies 28 at the bottom of the gantry legs 20 , between a land-based delivery location and a dockside location 32 along a body of seawater 34 . The crane 10 is moved to such position by the motorized wheel assemblies 28 so as to transfer containers between delivery vehicle trucks 36 and a shipping sea vessel 38 located in the seawater 34 at the dockside receiving location 32 . Container loads are thereby readily transferred by means of the crane 10 between the delivery vehicle trucks 36 respectively moved to positions between the crane legs 20 and the receiving shipping vessel 38 as hereinafter explained.
The rails 22 of the boom 14 as shown in FIGS. 5 , 6 and 7 have upper rail tracks 40 formed in the top edges thereof, while confronting lower trolley rail tracks 42 are formed in the lower inside portions sides of the rails 22 adjacent the bottom thereof. The upper rail tracks 40 receive wheels 44 of an upper trolley 46 , as shown in FIGS. 1 , 3 , 4 and 5 , while the lower rail tracks 42 receive wheels 60 of a lower trolley 50 as shown in FIG. 6 . The upper and lower trolleys 46 and 50 are thereby readily displaceable longitudinally along the boom 14 between the opposite end connectors 24 and 26 at the vertically spaced levels of the upper and lower rail tracks 40 and 42 .
Pivotally suspended from a cross-bar portion 52 of the upper trolley 46 between its side portion 54 on which the wheels 44 are mounted as shown in FIG. 5 , is a spreader element 56 . Loaded containers are adapted to be attached to such spreader 56 for transport by the upper trolley 46 along an upper travel path on the boom 14 between its opposite ends and for pivotal displacement relative thereto for enhancing reception and delivery. The lower trolley 50 is also provided with a cross-bar portion 58 between side portions on which the wheels 60 are mounted as shown in FIG. 6. A spreader element 62 is pivotally suspended from the cross-bar portion 58 of the lower trolley 50 for reception, delivery and transport of a loaded container 64 for example, between the opposite ends of the boom 14 along the lower trolley travel path established by the rail track 42 .
It will be apparent from the foregoing description that the lateral spacing between the boom rails 22 and corresponding dimensions of the trolleys 46 and 50 at different vertically spaced levels enables transport of all containers without obstruction, as well as to accommodate separate upper and lower rail shuttling movement of the trolleys 46 and 50 at the same time with containers thereon. Such shuttling movement of the upper trolley 46 with the container 64 thereon occurs on the rails 22 along the boom 14 as viewed in FIG. 1 to pass over the lower trolley 50 also moving therebelow along the boom 14 .
Thus, both the trolleys 46 and 50 may be utilized with maximum efficiency during a plurality of operational cycles for load transfer in opposite directions along the boom 14 . Accordingly, one of trolley 46 and 50 may be receiving a loaded container on its spreader 56 or 62 at one end of the boom 14 from the vehicles 36 as shown in FIG. 4 , while the other trolley 46 or 50 at the other end of the boom 14 is positioned for delivery of a loaded container from its spreader 56 or 62 at a ship-side location by drop off of a standard container 64 onto the sea vessel 38 as shown in FIG. 4 .
Obviously, other modifications and variations of the present invention may be possible in light of the foregoing teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced; otherwise than as specifically described
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Containers are transported by movement of upper and lower trolleys along vertically spaced travel paths established by laterally spaced rails formed in a boom supported in a horizontal position by suspension cables attached to a frame assembly through which the boom extends horizontally between container receiving and delivery locations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a heat exchanger and, more particularly, to a heat exchanger for use with high temperature materials.
2. Description of the Prior Art
In a typical propane or gas-fired hot air furnace, burner assemblies within the furnace inject a mixture of fuel and air into the inlets of a respective number of primary heat exchanger assemblies. After the fuel air mixture is combusted within the primary heat exchangers, the combustion gas travels through a serpentine flow path within the primary heat exchanger assemblies, exchanging some of the heat produced to the room air.
The more efficient gas-fired hot air furnaces increase the amount of heat energy transferred from the flue gas to the air to be heated. One manner in which the efficiency of the gas-fired hot air furnaces is being raised is by cooling the flue gases while still within the furnace to below their dew point. By cooling the flue gases to the point where condensation occurs, the latent heat of evaporation may be recovered as usable energy.
The recovery of the latent heat of evaporation is typically accomplished by adding a condensing heat exchanger to the primary heat exchanger and by passing air to be heated over the condensing heat exchanger and then through the primary heat exchanger. Some typical heat exchangers have been constructed from two engineering metal sheets such that a fluid flow is created when the two sheets are stamped and assembled.
As with the primary heat exchanger, the condensing heat exchanger must be constructed from a material having good heat transfer, adequate strength, minimum material thickness and preferably low manufacturing costs. The condensing heat exchanger, however, must additionally be constructed from a material having a high resistance to chemical attack. When the combustion gases condense within the condensing heat exchangers, a variety of acids may be produced, including carbonic and nitric acids, which can severely corrode bare steel and pit aluminum and copper with concentrations as little as 10 ppm (parts per million). As should be apparent, a condensing heat exchanger must be carefully designed for the environment within which the exchanger is placed.
Many condensing heat exchangers have been constructed from such materials as 300 Series stainless steel, which is a rather expensive material. Some less expensive engineering materials have been used with coatings that have been applied from a liquid or powder state. These coated engineering materials, however, have performed very poorly when used as a condensing heat exchanger since the coatings blister, crack, and fall off during the forming process of the condensing heat exchanger or while in service, thereby causing localized corrosion of the steel substrate.
An improved condensing heat exchanger is disclosed in U.S. Pat. No. 4,738,307 to Bentley, the disclosure of which is hereby incorporated by reference. The condensing heat exchanger in Bentley is formed from a single sheet of metal stamped to have an inlet, an outlet, and a flow passage between the inlet and outlet. The stamped sheet is laminated with a corrosion resistant material, preferably polypropylene, is folded at a center line, and then tabs on the sides of the exchanger are folded over and crimped to form the completed condensing heat exchanger. Because the single sheet is folded, one edge of the condensing heat exchanger is seamless, thereby reducing the risk of condensate leakage from the condensing heat exchanger.
While the condensing heat exchanger of the type disclosed in Bentley is less expensive than one constructed from Series 300 stainless steel, the condensing heat exchanger is still rather expensive. The use of polymer coated steel in Bentley's condensing heat exchanger is more expensive than many other types of materials, such as many plastics. The process for constructing Bentley's condensing heat exchanger is also lengthy since it involves a multi-step process including the steps of stamping, laminating, folding the two halves of the sheet, folding the tabs, and crimping the tabs.
With some heat exchangers in general, the heat exchangers have been constructed from polymers rather than stainless steel. For instance, U.S. Pat. No. 4,790,372 to Gemeinhardt et al. and U.S. Pat. No. 4,947,931 to Vitacco both disclose heat exchangers having passages formed from a thermoplastic or nylon polymer. If these heat exchangers were used as a condensing heat exchanger in a gas-fired hot air furnace, the heat exchangers would have to be constructed from a high temperature polymer material, which is rather expensive, in order to withstand the high inlet temperatures of the combustion gases. Thus, although a plastic material has a high corrosion resistance, a condensing heat exchanger constructed from a high temperature resistant polymer alone would not offer any cost savings.
A polymer heat exchanger, which would likely have a metallic header, would have other disadvantages as well. For instance, many furnaces have a variable speed room side blower. At low heating loads, special thermostats control the fan speed and burner firing rate so that they are at a reduced level, thereby increasing energy efficiency and comfort for the occupants by reducing the amount of noise through the ductwork. At these low heating loads, the condensation point of the combustion products is moved closer to the entrance of the secondary heat exchanger. This shift in location of the condensation point could expose the metallic header to the corrosive acids which are capable of rapidly degrading mild steel. The location of the condensation point can also shift in a non-variable speed condensing furnace, such as when the room air is below normal temperature. Thus, a need exists for a secondary heat exchangers which can accommodate location changes in the condensation point.
Another problem of a polymer exchanger having a metallic header relates to multi-poise operation. It is desirable in the home heating industry to produce furnaces which can be installed in a wide variety of orientations, such as horizontal right, horizontal left, vertical up, and vertical down, also known as multi-poise. A heat exchanger that can operate in the wide variety of orientations reduces the need to manufacture and stock furnaces designed for only one orientation. A secondary condensing heat exchanger, however, must accommodate for the flow of condensates through the heat exchanger and to a drain. Due to variations in orientation as well as other variations in the operation of a furnace, the condensates may likely flow down into the metallic header portion of the exchanger thereby degrading the header.
Other types of heat exchangers have been constructed from ceramic materials, such as glass. For instance, U.S. Pat. No. 4,653,575 to Courchesne describes an air-to-air heat exchanger comprised of a plurality of glass tubes through which the heated air travels. The ceramic materials, such as glass, are desirable since they can withstand generally higher temperatures than many plastic materials. For instance, U.S. Pat. No. 4,768,586 to Berneburg et al. discloses a ceramic heat exchanger which has a better heat resistance and corrosion resistance than most metallic exchangers. The ceramic materials, however, are more fragile and brittle and more easily crack or break during shipping, installation, or operation. Consequently, ceramic materials are not commonly used in many heat exchangers.
Therefore, it is still generally a problem in the art to provide a low cost heat exchanger which has a good heat transfer, adequate strength, and minimum overall system cost. It is further a problem in the art to provide a low cost condensing heat exchanger which can withstand both the high temperatures of the combustion gases and the corrosive acids within a gas-fired hot air condensing furnace.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a low cost heat exchanger.
Another object of the present invention is to provide a heat exchanger which can be used in corrosive environments.
Another object of the present invention is to provide a heat exchanger which can be used with high temperatures.
Another object of the present invention is to provide a heat exchanger which can safely be used in variable speed operation.
Another object of the present invention is to allow a condensing heat exchanger to operate safely in a plurality of orientations.
Additional objects, advantages, and novel features of the invention will be set forth in the description which follows, and will become apparent to those skilled in the are upon reading this description or practicing the invention.
To achieve the foregoing and other objects, a novel heat exchanger comprises a length of ceramic pipe having a first end forming an inlet to the heat exchanger and a second end opposite the first end. The ceramic pipe forms an initial portion of a fluid flow path through the heat exchanger. A polymer-based structure is connected to the second end of the ceramic pipe and forms the remaining portion of the fluid flow path through the heat exchanger. The geometry of the ceramic pipe is chosen so that the fluid flowing through the ceramic pipe is reduced from a first temperature at the first end of the ceramic pipe to a second temperature at the second end of the ceramic pipe near the polymer-based structure with the second temperature being less than a softening temperature of the polymer-based structure.
By using a ceramic material at the entrance to the heat exchanger, the temperature of the fluid may be reduced below the softening temperature of the polymer-based structure. As a result of the reduced temperature at the inlet to the polymer-based structure, the polymer-based structure may be formed from a lower cost polymer. The ceramic pipe is placed at the entrance to the heat exchanger because of its high temperature resistance and the polymer-based structure forms the remaining portion of the heat exchanger because of its high corrosion resistance and its lower cost.
In another aspect, the invention relates to a method of forming a heat exchanger comprising the steps of forming a ceramic pipe to have a certain length and to define an initial portion of a fluid flow path through the heat exchanger. A polymer-based structure is formed to define a remaining portion of the fluid flow path through the heat exchanger. The geometry of the ceramic pipe is selected so that a fluid flowing through the ceramic pipe is reduced from a first temperature at the inlet end of the ceramic pipe to a second temperature at the outlet end of the ceramic pipe near the polymer-based structure with the second temperature being less than a softening temperature of the polymer-based structure.
In yet a further aspect of the invention, a method for exchanging heat by using a heat exchanger comprises the steps of passing a heated fluid through a ceramic pipe having a certain geometry with the ceramic pipe defining an initial portion of a fluid flow path through the heat exchanger. After passing through the ceramic pipe, the fluid is routed to a polymer-based structure and is passed through the polymer-based structure, which defines a remaining portion of the fluid flow path through the heat exchanger. As the fluid is passed through the ceramic pipe, the fluid is cooled from a first temperature at an inlet to the ceramic pipe to a second temperature at the outlet of the ceramic pipe with the second temperature being below a softening temperature of the polymer-based structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in, and form a part of, the specification, illustrate certain preferred embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. In the drawings:
FIG. 1 is a perspective side view of a condensing heat exchanger according to a first embodiment of the invention;
FIG. 2 is a cross-sectional side view of the condensing heat exchanger in FIG. 1;
FIG. 3 is a diagram of an element of a heat exchanger;
FIG. 4 is a top plan view of a condensing heat exchanger according to a second embodiment of the invention; and
FIG. 5 is a top cross-sectional view of the condensing heat exchanger in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the invention. With reference to FIGS. 1 and 2, a heat exchanger 10 according to a preferred embodiment of the invention comprises a condensing heat exchanger 10 for use in a gas-fired hot air furnace. It should be understood that the principles of the invention may be applied to heat exchangers other than a condensing heat exchanger and may be used in environments other than in a gas-fired hot air furnace.
The condensing heat exchanger 10 has a condensing heat exchanger inlet 2 and a condensing heat exchanger outlet 4. Although not shown, the inlet 2 opens into a box that couples the primary heat exchanger to the condensing heat exchanger and the outlet 4 opens into a condensate collector. The condensing heat exchanger 10 has an internal fluid flow path 6 which winds downwardly from the inlet 2 to the outlet 4. The fluid flow path 6 is essentially the same as the fluid flow path of the condensing heat exchanger disclosed in U.S. Pat. No. 4,738,307 to Bentley, the disclosure of which has been incorporated by reference.
The condensing heat exchanger 10 is comprised of a ceramic piece of pipe 12 forming the inlet 2 to the condensing heat exchanger 10 and an initial portion of the fluid flow path 6 and a plastic structure 16 which defines the rest of the fluid flow path 6 as well as the outlet 4 for the condensing heat exchanger 10. An insulating wrap 14 is formed near the inlet 2 to the condensing heat exchanger 10 and is placed between the ceramic pipe 12 and the plastic structure 16. A portion 18 of the plastic structure 16 supports and is mounted to the inlet end of the ceramic pipe 12 while a portion 20 of the plastic structure 16 supports and is mounted to the opposite end of the ceramic pipe 12.
In operation, the gas exiting the primary heat exchanger and entering the condensing heat exchanger 10 at the inlet 2 is at a high temperature in the range of 300° to 450° F. The pipe 12, being formed from a ceramic material, has a high temperature resistance and reduces the temperature of the combustion gas as it travels through the ceramic pipe 12 transferring the heat to the room air. By the time the combustion gas reaches the portion of the fluid flow path 6 formed by the plastic structure 16, the temperature of the combustion gas has been reduced below the softening temperature of the plastic structure 16. In general, the softening temperature is the temperature at which the polymer in the structure 16 loses or has a significant drop in its elastic modulus such that the polymer is no longer structurally sound. Thus, by reducing the temperature below the softening temperature, the heated gas will not melt, deform, or degrade the plastic structure 16.
After the combustion gas enters the plastic structure 16, the gas continues to lose heat and products of the combustion begin to condense. The structure 16, being formed from a polymer, has a high corrosion resistance and can effectively and safely route the condensate to the condensate collector. The portion 18 of the plastic structure 16 is insulated from the ceramic pipe 12 by the wrap 14 whereby the temperature of the portion 18 is maintained below the softening temperature of the portion 18. The insulating wrap 14 may be comprised from many suitable insulating materials, such as Fiberfrax™ manufactured by Carborundum Co., Saffil™ by DuPont, or, preferably, Interam™ by 3M.
The condensing heat exchanger 10 can be safely used with variable speed and multi-poise operation. In addition to having a high temperature resistance, the ceramic pipe 12 also has an excellent resistance to corrosive acids. Thus, during variable speed or multi-poise operation, condensates may flow into the ceramic pipe 12 without degrading the ceramic material forming the pipe 12.
The pipe 12 may be formed from a number of ceramic or ceramic/glass types of materials. These materials include, but are not limited to, magnesium silicate, magnesium aluminum silicate, siliconized silicon carbide, sintered silicon carbide, silicon, silicon nitride, aluminum oxide, cordierite, zirconium oxide/aluminum oxide or mixtures thereof. A ceramic material which is preferred due to its low cost and its high temperature characteristics is a crystalline aluminosilicate, such as mullite.™ The formation of a ceramic pipe 12 is known to one skilled in the art and, accordingly, will not be described in any detail.
The plastic structure 16 may also be formed from a number of different types of polymers and is preferably formed from a low cost polymer, such as polypropylene, polyethylene, or styrene. The plastic structure 16 may additionally comprise one or more additives, such as a flame retardant. The plastic structure 16, however, need not be formed from a low cost polymer but could instead be formed from higher cost polymers, such as polyphenylene sulfide (PPS) or liquid crystal polymers, or middle cost polymers, such as polycarbonate or polyphenylene oxide-based materials. As will be apparent to those skilled in the art upon reading this description, any type of polymer which is resistant to corrosion from the condensate may be used in forming the structure 16 and additional examples of polymers include PPA, polyimide, PBT, or PET.
The type of polymer material that may be used in forming the plastic structure 16 is, in part, dictated by the temperature of the combustion gas entering the ceramic pipe 12, the heat transfer capability of the ceramic pipe 12, and the surface area of the ceramic pipe 12. In general, an element 30 of a heat exchanger is shown in FIG. 3 as having hot flue gas enter at temperature T 1 and exit at temperature T 2 . The average flue gas temperature T F can be determined as follows:
T.sub.F =(T.sub.1 +T.sub.2)/2 (EQ. 1).
The element 30 has a length L, a diameter D, and thus has a surface area A equal to πDL. In the figure, T A is the constant free stream of air temperature, T W is the bulk internal fluid temperature, and T w is the temperature of the wall of the element 30. The conduction of heat through the wall of the heat exchanger element 30 is much greater than the convection of heat through the flue side and the convection of heat on the air side. The heat transfer process can therefore be simplified based upon the convection of heat on the flue and air sides of the heat exchanger element 30.
The heat transfer from the hot flue gas is given by:
q=mc.sub.p (T.sub.1 T.sub.2) (EQ. 2),
where m is the mass flow rate and c p is the specific heat.
The heat transfer from the hoe flue gas can also be expressed as follows:
q=A(T.sub.F -T.sub.A)/(1/h.sub.i +1/h.sub.o) (EQ. 3),
where h i and h o are the heat transfer coefficients at the inside and outside of the heat exchanger element 30.
By simultaneously solving the above three equations by well known numerical techniques, the three unknowns of the fluid temperature T F , the temperature T 2 , and the heat transfer q can be determined. Consequently, by proper selection of the length, diameter, and material of the ceramic pipe, it is possible to reduce the temperature at the outlet of the ceramic pipe 12 below the softening temperature of a particular polymer forming the structure 16. For instance, if the structure 16 is formed with polypropylene, then the ceramic pipe 12 must reduce the temperature of the combustion gas to below 300° F., which is the softening temperature of polypropylene.
The formation of the plastic structure 16 will be apparent to one skilled in the art and may be formed by any suitable process. For instance, the plastic structure 16 may be injected molded into two halves with the two halves being joined together to form the complete structure 16. The two halves of the structure 16 may be joined together in a number of ways, such as by vibration welding or by using a room temperature vulcanizing silicon rubber adhesive, commonly known as "furnace paste." The structure 16 could alternatively be formed in a single assembly by blow molding or by soluble-core or lost-core molding. Even though blow molding and soluble-core molding are generally more expensive methods than injection molding, the blow molding and soluble-core molding processes may be preferred over injection molding because they do not produce any seams that might fail and because they do not require an additional assembly process. Other variations in the formation process, such as flow forming or compression molding of a thermoset material, will become apparent to those skilled in the art.
In the embodiments shown, the plastic structure 16 is formed to have portions 18 and 20 surrounding the two ends of the ceramic pipe 12. The two portions 18 and 20 may be formed around the ceramic pipe 12 simultaneously with the formation of the entire structure 16, for instance by injection molding the portions 18 and 20 around the ceramic pipe 12. The portion 20 of the structure 16 would support the ceramic pipe 12 as well as seal the ceramic pipe 12 to the structure 16. The portion 18 of the structure 16 would support the inlet end of the ceramic pipe 12 and, together with the insulating wrap 14, would protect the ceramic pipe 12 from damage during shipping or installation.
A heat exchanger 40 according to a second embodiment of the invention, as shown in FIGS. 4 and 5, comprises a plurality of ceramic pipes 42 arranged linearly along the width of the heat exchanger 40. A sheet metal header 44 is attached to inlet ends of the ceramic tubes 42 and a polymer-based structure 46 is attached to outlet ends of the ceramic tubes 42.
The heat exchanger 40 may comprise a condensing heat exchanger 40 in a gas-fired hot air furnace with the heat exchanger 40 receiving combustion gas from a primary heat exchanger through the header 44. The temperature of the combustion gas is reduced by the geometry of the ceramic pipes 42 to below a softening temperature of the polymer-based structure 46. Consequently, the polymer-based structure 46 may be formed from a lower cost polymer.
The sheet metal header 44 is attached to the ceramic pipes 42 with an inlumescent ceramic fiber seal, such as Interam™. The ceramic pipes 42, in this example, have a 0.5 inch outer diameter and may comprise any suitable ceramic material, such as any of the materials forming the ceramic pipe 12. Similarly, the polymer-based structure 46 may comprise any suitable polymer, such as any of the ones forming the structure 16.
The polymer-based structure 46 is formed with a plurality of heat transfer enhancements 48 which extend completely through the polymer-based structure 46 and which direct the flow of the combustion gas through passages between the heat transfer enhancements 48. The heat transfer enhancements 48 also direct any condensates that may form within the heat exchanger 40 to a bottom portion of the heat exchanger 40. The polymer-based structure 46 has a set of mounting holes 50 for positioning the heat exchanger 40 relative to the primary heat exchanger within the furnace.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.
For example, a heat exchanger according to the invention may be formed with any number of ceramic pipes for receiving a heated gas and for cooling the gas to below a softening temperature of a polymer-based structure attached to the ceramic pipe or pipes. Also, the polymer-based structure, as evident by the two embodiments, is not limited to any specific shape but may instead define any suitable flow path through the heat exchanger.
The embodiments were chosen and described in order to explain the principles of the invention and their practical application to thereby enable others skilled in the art to utilize the invention and various embodiments and with various modifications as are best suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims.
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A heat exchanger for use as a condensing heat exchanger in a gas-fired hot air furnace has a ceramic pipe forming an initial portion of a fluid flow path through the heat exchanger. The ceramic pipe receives the combustion gases from a primary heat exchanger and reduces the temperature of the combustion gases to below a certain temperature. A polymer-based structure is connected to the ceramic pipe and forms the remaining portion of the fluid flow path through the heat exchanger. The geometry and orientation of the ceramic pipe is selected so that the certain temperature of the combustion gases exiting the ceramic pipe is less than the softening temperature of the polymer-based structure. The resultant heat exchanger combines the high temperature and corrosion resistance of ceramic materials with the low cost and high corrosion resistance of polymer materials. As a result, a low cost heat exchanger can be produced which can withstand both the high temperatures of the combustion gases as well as the corrosive properties of the condensates from the combustion gases.
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TECHNICAL FIELD
[0001] The present invention relates to vehicles having lift arms such as skid-steer loaders, and more particularly to a quick attach device for releasably connecting a variety of working implements with a carrier mounted to the lift arms of such vehicles.
BACKGROUND OF THE INVENTION
[0002] Working vehicles such as skid-steer loaders or other small utility loaders have lift arms that can be used with various work implements such as buckets, blades, and lift forks. Various mechanisms have been proposed to provide quick interchange of the work implements so the same loader can be used for different work functions.
[0003] Working vehicles frequently have tool carriers supported at the end of their lift arms. These carriers are adapted to be attached to a variety of implements. To simplify and expedite the mounting and removal of various implements, the carriers are equipped with quick-attach devices. The carrier and/or quick-attach devices typically include positioning structures to orient and locate one part of the carrier relative to the implement as well as a latching structure to secure the implement to the carrier.
[0004] Some quick-attach mechanisms rely on pins which must be inserted into aligned holes in the implement. This type of mechanism can require careful and time consuming alignment of the pins and holes. Additionally, dirt or other obstructions may make insertion and removal of the pins somewhat difficult. It would be desirable to visually inform the operator of the existence of a misalignment or non-engagement of the pin with the implement. Additionally, it would be desirable to provide some mechanical advantage to assist in engaging the pin with the implement, such as during a misalignment condition.
[0005] Accordingly, it would be desirable to provide a coupling assembly which avoids deficiencies in the prior art and is easy to use and provides for efficient releasable coupling of an implement to a working vehicle.
SUMMARY OF THE INVENTION
[0006] Accordingly, it would be desirable to provide a coupling assembly which avoids deficiencies in the prior art and is easy to use and provides for efficient releasable coupling of an implement to a working vehicle.
[0007] Toward these ends, there is broadly provided a coupling assembly including a tool carrier attached to the work vehicle and supporting a pin guide. A pin is supported upon the carrier by the pin guide and interacts with one or more cam surfaces supported by the carrier. During rotation of the pins, the cam surfaces transfer an axial force to the pin to assist in the extraction or insertion of the pins into the implement. In one embodiment, the pin has a graspable handle which may be rotated and axially moved by an operator. As a result, the pin and cam surfaces cooperate to convert a rotational motion of the pin handle into a linear motion assisting in the extension of the pin into its engaged position within an implement aperture or in the retraction of the pin into its disengaged position so that implement may be removed.
[0008] The cam surface which engages the pin may be provided upon a small insert or upon the guide block or both. In one embodiment, two cam surfaces are provided so that axially forces may be transferred to the pin to assist in both the extraction and insert of the pin relative to the implement.
[0009] In a preferred embodiment of this invention, the improved coupling assembly includes a carrier supporting a pair of similar pin assemblies, each as described above.
[0010] One object of the present invention is the provision of a visual indication that the pin is not fully engaged with the implement. An operator may visually reference the pin assembly to determine that the pin is properly engaged with the implement.
[0011] Yet another object of the present invention is the provision of a locking mechanism which prevents a pin from disengagement under axial-only force. As described herein, to disengage the pin from the implement an axial and rotation force must be applied.
[0012] These and other objects, features, and advantages of the invention will be evident from the following description of the preferred embodiment of this invention, with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective view of a working vehicle having an implement carrier according to the present invention and positioned relative to an implement.
[0014] [0014]FIG. 2 is a perspective view of an implement and carrier according to the present invention, wherein the pin assembly is illustrated in an engaged orientation.
[0015] [0015]FIG. 3 is a detailed exploded view of a pin assembly and carrier according to the present invention.
[0016] [0016]FIG. 4 is an elevational view of a pin assembly and carrier of FIG. 1, illustrating the engaged orientation of the elements.
[0017] [0017]FIG. 5 is an elevational view of a pin assembly and carrier of FIG. 1, illustrating an intermediate orientation of the elements.
[0018] [0018]FIG. 6 is an elevational view of a pin assembly and carrier of FIG. 1, illustrating the disengaged orientation of the elements.
[0019] [0019]FIG. 7 is a cross-sectional view of the pin assembly and carrier taken along lines 7 - 7 of FIG. 4.
[0020] [0020]FIG. 8 is a cross-sectional view of the pin assembly and carrier taken along lines 8 - 8 of FIG. 5.
[0021] [0021]FIG. 9 is a cross-sectional view of the pin assembly and carrier taken along lines 9 - 9 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] While this invention can be embodied in many different forms, there is shown in the drawings and described in detail, a preferred embodiment of the invention. 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 embodiment illustrated.
[0023] For ease of description, the coupling assembly embodying this invention will be described in a normal upright operating position and such terms as upper, lower, upwardly, downwardly, will be used with reference to this position. It will be understood, however, that the coupler assembly embodying this invention can be used in an orientation other than the position described.
[0024] Referring to the FIGURES, a tractor or utility loader 10 having a lift arm assembly 12 and dump cylinder 14 , and commonly referred to as a skid steer loader, is shown in association with a work implement 16 , a bucket. The illustrated tractor 10 is a DINGO brand compact utility loader manufactured by The Toro Company. As described in more detail herein, a carrier 18 engages implement 16 . Alternative tractors 10 or utility loaders may utilize a coupling assembly according to the present invention.
[0025] The present invention, a coupling assembly, can be used with other mechanized equipment having a lift arm assembly and can be used to couple a variety of implement such as a bucket, blade, or fork assembly, etc. to a carrier of a machine. The term “carrier” is meant to broadly cover an intermediate structure between a loader 10 and an implement 16 . Typical carriers 18 are movably connected to lift arms 12 of loader 10 so that implement 16 may be raised or lowered by lift cylinders 13 attached between lift arms 12 and a frame of loader 10 . A variety of carriers 18 could be utilized to practice the present invention. Alternative carriers 18 may not have a “plate-like” structure 32 for engaging implement 16 , but instead may have a plurality of contact points between carrier 18 and implement 16 .
[0026] Implement 16 is provided with an attachment structure 20 which includes a downwardly facing recess 22 and an upwardly facing member 24 having a pair of apertures 26 for engaging tractor 10 . Attachment structure 20 is designed to cooperate with carrier 18 as further described herein to facilitate alignment and connection between the elements. Various implements, such as a bucket, auger, loading forks and the like having associated attachment structure 20 can be connected to carrier 18 .
[0027] Referring to FIGS. 1 and 2, carrier 18 is attached to lift arm assembly 12 with 3 pins 30 , (2 pins are shown in FIG. 1). Carrier 18 includes a plate surface 32 for engaging a generally flat surface 34 of implement 16 . Pins 30 pass through appropriately sized apertures 34 , 36 upon carrier 18 . Dump cylinder 14 is connected at an upper aperture 36 , allowing carrier 18 to pivot in operation relative to lower pins 30 . Carrier 18 further includes a plurality of guide block structures 38 for slidably receiving a pair of pins 40 of the coupling structure of the present invention. Guide block structures 38 include a pair of upper guides 38 A and a pair of lower guides 38 B.
[0028] Carrier 18 is selectively connected to attachment structure 20 of implement 16 through the coupling assembly of the present invention. As described herein, the coupling assembly of the present invention provides a selective connection between attachment structure 20 of implement 16 and carrier 18 of loader 10 .
[0029] In overview, a preferred embodiment of the coupling assembly of the present invention includes a pair of pins 40 , upper and lower inserts 42 , 44 , a spring 46 , and upper and lower guide blocks 38 A, 38 B.
[0030] Referring particularly to FIG. 3, pin 40 has a handle 50 adapted to be grasped by an operator during a coupling method as described herein. Pin 40 is slidably received within bores 52 of both upper guide 38 A and lower guide 38 B of mounting frame 18 so that pin 40 may both rotate and translate relative to its longitudinal axis. Lower guide 38 B includes a grease fitting 54 permitting lubrication of the coupling assembly.
[0031] Lower guide 38 B further includes a cam surface 56 . A shoulder 58 is positioned at a top portion of cam surface 56 . As described hereinafter, cam surface 56 may be engaged by lower insert 44 causing pin 40 to rotate during a coupling operation. In this embodiment, cam surface 56 is an inclined surface which is generally planar. Alternative cam surfaces 56 may include curves or more complex surfaces. As used herein the term “cam surface” means a surface which is at least partially oblique relative to an axis passing through bore 52 centers.
[0032] Upper insert 42 , spring 46 , and lower insert 44 are positioned relative pin 40 between upper guide 38 A and lower guide 38 B. Inserts 42 , 44 and spring 46 are sized to slidably receive pin 40 . Lower insert 44 is connected to pin 40 by a small pin 60 passing through an aperture 62 in insert 44 and an aperture 64 in pin 40 . As a result, lower insert 44 and pin 40 rotate and move together. Upper insert 42 includes a second cam surface 70 . As described herein, second cam surface 70 may be engaged by lower insert 44 causing pin 40 to extend into its engaged position. Upper insert 42 includes a birfucated end 72 which engages a protrusion 74 of carrier 18 . Bifurcated end 72 prevents upper insert 42 from rotating relative to pin 40 . Spring 46 is compressed during assembly so that spring 46 biases apart inserts 42 , 44 .
[0033] Operation of the coupling assembly may be described with reference to the figures. In overview, attachment and detachment of the implement 16 is made by manually grasping pin handle 50 to engage and retract pin 40 relative to apertures 26 of implement 16 .
[0034] As depicted in FIG. 1, loader 10 may engage implement 16 by retracting pins 40 , tilting carrier 18 relative to implement 16 , moving the loader 10 forward, and inserting the upper lip of carrier 18 into the downwardly facing recess 22 of implement 16 . FIGS. 1, 6 and 9 illustrate pins 40 in their retracted position. With the upper lip of carrier 18 retained within downwardly facing recess 22 , carrier 18 may be rotated by action of cylinder 14 so that the plate surface 32 engages flat surface 34 of implement 16 . At this point, pin 40 handles 50 may be rotated to engage pins 40 into apertures 26 of implement 16 . FIGS. 2, 4 and 7 illustrate pins 40 in their extended position (implement engaged position).
[0035] To remove the implement 16 , pin 40 handles 50 are rotated and lifted to retract pins 40 from apertures 26 of implement 16 . The implement 16 may then be lowered to the ground and carrier 18 rotated so that the upper lip of carrier 18 is removed downwardly facing recess 22 . Additional features of the coupling assembly of the present invention are revealed by closer examination of FIGS. 2 through 7.
[0036] FIGS. 2 - 7 illustrate three orientations of pin 40 relative to mounting plate 18 . FIGS. 2, 3, 4 and 7 illustrate the coupling assembly in its engaged position, wherein pins 40 are extended from the bottom of carrier 18 and may be engaged with apertures 26 of implement 16 to connect implement 16 to loader 10 . FIGS. 5 and 8 illustrate the coupling assembly in an intermediate position with handle 50 partially rotated from an engaged position. Pin 40 in intermediate orientation is not engaged with implement 16 . When handle 50 is in the intermediate position of FIGS. 5 and 8, handle 50 provides a visual indication to the operator that pin 40 is not engaged with implement 16 . FIGS. 6 and 9 illustrate the coupling assembly in its detached position, wherein pins 40 are retracted within carrier 18 allowing the implement 16 to be detached from loader 10 .
[0037] To couple implement 16 to carrier 18 , pins 40 are each placed into respective retracted positions as illustrated in FIGS. 6 and 9 and carrier 18 is inserted into attachment structure 20 of implement 16 , typically by moving loader 10 into engagement with implement 16 . In the retracted position, a flat 78 of lower insert 44 fully engages shoulder 58 of lower guide 38 B as spring 46 biases upper insert 342 and lower insert 44 apart. Next an operator grasps pin handle 50 and rotates pin 40 toward its engaged orientation. As pin 40 and lower insert 44 are rotated into the intermediate position of FIGS. 5 and 8, a portion of flat 78 engages shoulder 58 .
[0038] As pins 40 are further rotated past an intermediate position toward an engaged (extended) position, flat 58 may engage cam surface 56 as spring 46 biases inserts 42 , 44 apart. Alternatively, if pin assembly is dirty or a lower aperture is partially blocked or misaligned with aperture 26 of implement 16 an upper portion 80 of lower insert 44 may engage second cam surface 70 so that as pin 40 is rotated, a downward force is transferred through second cam surface 70 to insert 44 forcing pin 40 to align with implement aperture 26 and extend thereinto.
[0039] In this manner, a positive alignment and engagement between pin 40 and implement aperture 26 is provided when pin 40 is rotated from its disengaged position into its engaged position. In the absence of second cam surface 70 , pin handle 50 could be rotated into its engaged position without pin 40 extending into position within implement aperture 26 . The pin 40 , lower insert 44 , and second cam surface 70 cooperate to convert a rotational motion of handle 50 into a linear motion assisting in the extension of pin 40 into its engaged position within implement aperture 26 .
[0040] If pin 40 is blocked or misaligned relative to apertures 26 , the operator will be prevented from further rotating pin handle 50 toward the engaged orientation of FIGS. 2 , 3 , 4 and 7 as upper surface 80 of lower insert 44 engages and is blocked by cam surface 70 of upper insert 42 . In this regard, a visual indication may be presented to the operator that a misalignment and non-engagement situation exists. In some situations, upon subsequent alignment of pin 40 with aperture 26 (such as upon rocking the implement, etc.), spring 46 may bias insert 44 causing pin 40 to rotate into its engaged orientation. An operator may visually monitor the pin 40 transition from an intermediate non-engaged position to the engaged position, and may facilitate the transition by manipulating the implement 16 (manually or through operation of dump cylinder 14 and/or lift cylinder 13 ) so that pin 40 aligns with aperture 26 .
[0041] Regarding the engaged position, as illustrated in FIGS. 2, 3, 4 and 7 , an inclined surface 82 of lower insert 44 fully engages cam surface 56 . Pin 40 is prevented from substantially displacing in an axial direction, e.g., upwardly, as an upper surface 80 of the lower insert 44 engages and is blocked by a lower surface 84 of the upper insert 42 upon slight axial movement. This provides a positive lock mechanism which prevents pin 40 from axially displacing when in its engaged position. As a result, forces transferred in an upward axial direction at the pin 40 bottom or upward axial forces alone at the handle 50 will not disengaged pin 40 from its engaged position. As described hereinafter, handle 50 must be both axially lifted and rotated to retract pin 40 into carrier 18 .
[0042] To disengage implement 16 from carrier 18 , pin handle 50 is grasped and rotated. Pin 40 may be upwardly lifted by the operator as pin handle 50 is rotated. Alternatively, in the absence of an upward force by the operator, lower insert 44 positively engages cam surface 56 as the pin handle 50 is rotated to cause an upward force retracting pin 40 . In this manner, as pin handle 50 is rotated, cam surface 56 may provide an upward force to assist in the retraction of pin 40 from implement aperture 26 . The pin 40 , lower insert 44 , and cam surface 56 cooperate to convert a rotational motion of the handle 50 into a linear motion assisting in the retraction of pin 40 into its disengaged position.
[0043] Those skilled in the relevant arts will appreciate that a variety of connections may be utilized to connect carrier 18 to lift arm assembly 12 . Additionally, a variety of differently configured attachment structures 20 and carrier 18 may be utilized in conjunction with the coupling assembly of the present invention. For example, a different attachment structure may include a pair of flange structures, each for separately engaging one of a pair of upper lips of a carrier.
[0044] Other alternatives to the illustrated embodiment may include forming the second cam surface 70 not on a separate upper insert 42 , but instead as a portion of carrier 18 , e.g. a machined second cam surface being integral with carrier 18 . Lower insert 44 may be formed as an integrated part of pin 40 . The lower insert 44 features of an upper surface 80 to engage the second cam surface 70 and a lower surface 82 to engage the first cam surface 56 may be formed into a single pin, rather than a two-piece pin and insert 42 , 44 of the illustrated embodiment. For example, a pin 40 may have one or more weldment or other protrusion which engage cam surfaces 56 , 70 causing the pin to extend or retract as the pin is rotated. Yet other pins (not shown) for engaging cam surfaces 56 , 70 and converting a rotation motion into a linear motion would be practicable.
[0045] In another embodiment, handle 50 may be eliminated and a hydraulic or other actuator may be used to provide a rotation motion to a pin 40 . The term actuator as used herein means any type of power actuator that provides for extension or retraction under control of an operator. Appropriate linkages between an actuator and a pin 40 would be within the scope of those of ordinary skill in the art. In this regard a positive lock and release mechanism may be provided as the linear motion of the actuator causes pin 40 to rotate and extend or retract in response to engagement with cam surfaces 56 , 70 .
[0046] Various other modifications can be made in the present invention without departing from the scope and spirit of the invention.
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An improved coupling assembly and method of use are disclosed herein to include a tool carrier attached to a utility loader or other work vehicle and supporting a pin guide. A pin is supported upon the carrier by the pin guide and interacts with one or more cam surfaces supported by the carrier. During axial rotation of the pin, the cam surface transfers a force to the pin to assist in the extraction and/or retraction of the pin into the implement. In one embodiment, the pin has a user graspable handle which may be rotated and axially moved by an operator. A visual indication that the pin is not fully engaged with the implement is also provided. Additionally, a locking mechanism is provided which prevents a pin from disengagement with the implement.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 08/612,608, filed Mar. 8, 1996 now abandoned, which in turn is a continuation of U.S. Ser. No. 08/461,371, filed Jun. 5, 1995, now abandoned, which in turn is a continuation of U.S. Ser. No. 08/081,687, filed Jun. 24, 1993, now abandoned, which in turn is a continuation-in-part of U.S. Ser. No. 07/841,578, filed Feb. 26, 1992, now abandoned.
FIELD OF THE INVENTION
This invention relates to sealing devices for rotating shafts, where a sealed fluid is employed to generate hydrostatic-hydrodynamic or aerostatic-aerodynamic forces between interacting face-type sealing elements, one stationary, another rotating. These forces provide for slight separation and non-contacting operation of the above sealing elements, thereby minimizing face wear and friction power losses while maintaining low fluid leakage.
BACKGROUND OF THE INVENTION
Rotary fluid film face seals, also called non-contacting face seals, are usually applied to high-speed, high-pressure rotating equipment, where the use of ordinary mechanical face seals with face contact would result in excessive heat generation and wear. Non-contacting operation avoids this undesirable face contact at times when the shaft is rotating above certain minimum speed, which is called a lift-off speed.
There are various ways of accomplishing the above non-contacting operation, of which one of the most successful includes the application of a shallow spiral groove pattern to one of the sealing faces. The sealing face opposite the face is relatively flat and smooth. The face area where these two sealing faces define a sealing clearance is called the sealing interface.
The above-mentioned spiral groove pattern on one of the sealing faces normally extends inward from the outer circumference and ends at a particular face diameter called the groove diameter.
It is important to end the spiral pattern at the groove diameter, which is larger than the inner diameter of the seal interface. The remaining non-grooved area between the groove diameter and the inner interface diameter serves as a restriction to fluid outflow. Fluid delivered by the spiral pattern must pass through this restriction and it can do so only if the sealing faces separate. The way this works is through pressure build-up. Should the faces remain in contact, fluid will be compressed just ahead of the restriction, building up pressure. Pressure will cause separation force, which will eventually become larger than the forces that hold faces together. In that moment the sealing faces separate and allow the fluid to escape. During operation of the seal, an equilibrium establishes itself between fluid inflow through spiral pumping and fluid outflow through face separation. Face separation is therefore present as long as the seal is operating, which means as long as one face is rotating in relation to the opposite face. Yet spiral pumping is not the only factor that will determine the amount of the separation between the sealing faces. Just as the spirals are able to drive the fluid into the non-grooved portion of the sealing interface past the groove diameter, so can the pressure differential. If enough of a pressure difference exists between the grooved end of the interface and the non-grooved end, fluid will also be forced into the non-grooved portion of the interface, thereby separating the faces and forming the clearance.
Both ways in which clearance can be formed between the sealing faces, one with speed of rotation, the other with pressure differential, are distinct and separate, even though on the operating seal the effects of both combine. If there is no pressure difference and the seal face separation occurs strictly due to face rotation, forces due to fluid flow are known as hydrodynamic forces, if the fluid sealed is a liquid; aerodynamic forces, if the fluid sealed is gas.
On the other hand, if there is no mutual rotation between the two sealing faces and face separation is strictly the consequence of pressure differential between both ends of the sealing interface, forces due to fluid flow are called hydrostatic forces, should the fluid sealed be liquid; aerostatics forces, should the fluid sealed be gas. In the following, the terms hydrostatic and hydrodynamic are used for both liquid and gas effects, since these terms are used more often than aerostatic and aerodynamic and latter has also another meaning.
A typical spiral groove seal needs to provide acceptable performance in terms of leakage and the absence of face contact during all regimes of seal operation. It must do so not only at top speed and pressure, but also at standstill, at start-up, acceleration, at periods of equipment warm-up or at shutdown. At normal operating conditions, pressure and speed vary constantly, which results in continuous adjustments to the running clearance. These adjustments are automatic; one of the key properties of spiral groove seals is their self-adjustment capability. On change in speed or pressure, the face clearance adjusts automatically to a new set of conditions. Hydrostatic and hydrodynamic forces cause this adjustment.
The operating envelope of speeds and pressures is usually very wide and a seal design of necessity must be a compromise. For its performance to be acceptable at near-zero speed or pressure, it is less than optimum at operating speed and pressure. This is simply due to the fact that, both in terms of pressure and speed, the seal has to be brought up to operating conditions from zero speed and zero pressure differential.
Especially critical to seal operation is the start-up. If the seal is applied to a centrifugal gas compressor, the full suction pressure differential is often imposed onto the seal before the shaft starts turning. This presents a danger in that the sealing faces will lock together with friction. Face lock results when the hydrostatic force is insufficient to counter pressure forces that maintain the seal faces in contact. Face lock can lead to seal destruction, in which excessive break-away friction between contacting seal faces can cause heavy wear or breakage of internal seal components.
First then, spiral grooves must be able to separate faces hydrodynamically for full speed non-contacting operation. This normally requires fairly short and relatively deep spiral grooves. Second, the spiral grooves must be able to unload faces hydrostatically for start/stops to prevent face lock. For this, the grooves have to be extended in length. The extended grooves in turn cause more separation and leakage during full speed operation. The full speed leakage of a typical 3.75 inch shaft seal With short and relatively deep spirals would be about 0.9 SCFM (this stands for Standard Cubic Feet per Minute) at 1,000 psig and 10,000 rpm. However, full speed leakage for such a seal with extended grooves would reach 2.4 SCFM at the same conditions, almost triple the previous value. The constant burden of larger-than necessary leakage represents significant operating costs.
Prior art, leading to the current spiral groove design practice goes back to U.S. Pat. No. 3,109,658 issued to Barrett and others. Two opposing spiral grooves pumped oil against each other, which developed a liquid barrier capable of sealing gas. Such an arrangement was limited in pressure as well as speed capability, inherent in the use of liquid forces to seal gas.
The next important prior art resides in U.S. Pat. No. 3,499,653 issued to Gardner. While incorporating a currently popular interface design with partial spiral grooves, Gardner relied heavily on hydrostatic effects, in which an interface gap would be designed with taper shape narrower at the non-grooved end and wider at the spiral grooves. The effect of the spiral grooves and therefore the hydrodynamic forces would thus be suppressed, since spiral groove pumping would become less effective across wider gaps. This likewise affected the stability of the seal and limited its top pressure and speed capability.
Subsequent major prior art was granted by U.S. Pat. No. 4,212,475 to Sedy. Here the fact, that the spiral groove itself acts as a hydrostatic as well as hydrodynamic pattern was used to eliminate the need for taper shape of the gap so a considerable degree of spiral groove hydrodynamic force could then be applied to impart a self-aligning property to a sealing interface. The self-aligning property would force the sealing interface back towards parallel position, regardless of whether deviations from parallel position curing seal operation occurred in radial or tangential directions. This resulted not only in an overall improvement of the stability of seal operation, but also in increased performance limits in terms of pressure and speed.
SUMMARY AND OBJECT OF THE INVENTION
This invention is aimed at improvement in the performance of the spiral groove seal as well as further increase in its pressure and speed limits beyond those within reach of prior art designs. The invention combines two spiral groove patterns into one with the aim of providing a seal with a hydrostatic opening force for safe start-stops but without the penalties of excessive hydrodynamic effects, large clearance and high leakage.
In a preferred embodiment of this invention, one spiral groove pattern is designed and optimized to remove seal face lock condition while it remains closed with near-zero leakage; another spiral groove pattern is designed for optimum performance of the seal at operating speed and pressures. Thus it is no longer necessary to compromise one and only spiral groove pattern of prior art to satisfy both start/stop and operating conditions simultaneously. Resulting seal operates at lesser leakage rates, is therefore capable of running at higher speeds and pressures, before excessive leakage rates may cause onset of instability.
Other objects and purposes of the invention will be apparent to persons familiar with structures of this general type upon reading the following specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial quarter section view in elevation of a seal, constructed in accordance with this invention, showing the relative position of the various parts, when the shaft is rotating.
FIG. 2 is an end view in a section, taken along line 2--2 in FIG. 1, illustrating one of the sealing rings of the preferred embodiment of this invention.
FIG. 3 is a fragmentary view in section, taken along the line 3--3 in FIG. 2 through the spiral grooves in the sealing ring surface and showing the groove portions of uniform depth.
FIG. 4 is a schematic side elevation view in section of the sealing interface and an axially movable sealing ring with depiction of axial forces, acting on it.
FIG. 5 is a pressure-clearance diagram, showing hydrostatic and hydrodynamic clearances for four different spiral groove configurations.
FIG. 6 is a magnified view in section of two flat surfaces in contact.
FIG. 7 is a schematic end view similar to FIG. 2, showing another embodiment.
FIG. 8 is a fragmentary view in section, similar to FIG. 3, showing yet another embodiment.
FIG. 9 is a fragmentary view in section, similar to FIG. 8, showing a further embodiment.
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 structure and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
Referring first to FIG. 1, there is shown the invention and its environment. This environment comprises a housing 10 and a rotatable shaft 12, extending through said housing. The invention is applied to seal a fluid within the annular space 14 and to restrict its escape into the fluid environment at 16. Basic components of the invention comprise an annular, axially movable sealing ring 18, having a radially extending face 19 in sealing relationship with a radially extending face 21 of an annular rotatable sealing ring 20. The sealing ring 18 is located within cavity 15 of housing 10 and held substantially concentric to rotatable sealing ring 20. Between housing 10 and the sealing ring 18 is a plurality of springs 30, spaced equidistantly around the cavity 15 of housing 10. Springs 30 urge the sealing ring 18 into engagement with the sealing ring 20. An O-ring 38 seals the space between the sealing ring 18 and the housing 10. The sealing ring 20 is retained in the axial position by a sleeve 32. Sleeve 32 is concentric with and locked on the shaft 12 by locknut 34, which is threaded on shaft 12 as shown. O-ring seal 36 precludes leakage between the sealing ring 20, and the shaft 12. In operation, radially extending face 21 of the sealing ring 20 and radially extending face 19 of the sealing ring 18 are in sealing relationship, maintaining very narrow clearance, generated by combination of two spiral groove patterns 22 and 24, chemically etched into the sealing face 21 of the sealing ring 20. Arrangements with said spiral patterns etched into the sealing face 19 of the sealing ring 18 are also effective. Said narrow clearance prevents generation of friction heat and wear, yet limits outflow of the sealed fluid, present at space 14.
FIG. 2 shows an elevation view of the sealing face 21 of the sealing ring 20 with two superimposed patterns of spiral grooves 22 and 24 in the direction 2--2, according to FIG. 1. Spiral grooves 22 and 24 shown are directed counterclockwise and inward for a particular direction of shaft rotation and will be directed clockwise and inward for the opposite direction of shaft rotation. The inner spiral groove pattern 24 is an extension of outer spiral groove pattern 22 and they are separated by concentric circumferential step segments 26. Inner end of spiral groove pattern 24 is delimited by concentric circumferential step segments 28.
FIGS. 3, 8 and 9 show spiral grooves 22 and 24 in section, taken along the line 3--3 in FIG. 2. Spiral groove 22 is recessed into sealing face 21 between step segment 26 and outer periphery of sealing ring 20, forming relatively deep depressions. Spiral grooves 24 are adjacent to spiral grooves 22 at step segments 26 and are delimited by step segments 26 and 28, forming relatively shallow depressions. The steps 26 at the ends of the spiral grooves 22 define an abrupt or damlike transition between the grooves 22 and 24, although such steps obviously do not have to extend perpendicularly as illustrated by FIG. 3.
FIG. 4 shows the axially movable sealing ring, positioned opposite another sealing ring of simple spiral groove pattern per prior art, both separated by clearance C. Spiral groove pattern shown is delimited by dimensions A and B. On both sides of axially movable sealing ring is the depiction of axial forces in equilibrium. Axial forces are shown as multiple arrows, pictured within a field, defined by pressure distribution across front and the back of the sealing ring shown. Should these pressure distributions change, force balance will change and resulting force difference will shift the sealing ring to readjust the face separation, whereupon forces will again restore their equilibrium.
In a wide envelope of seal operating points, the very first one is the moment, when shaft begins to turn. Normally at that point, seal is already holding pressure differential. What is needed in order to start turning the shaft is slight clearance C or zero clearance, but on the verge of opening, the case when closing and opening forces are nearly equal. What is to be avoided is large clearance, associated with heavy leakage and zero clearance with closing force much larger than opening force. Then sealing faces would be locked together by friction and should shaft start turning, seal damage may result.
Condition of zero clearance on the verge of opening is most desirable and according to this invention also attainable at wide range of sealed pressures. At this condition, equipment can stand by at full pressure for months, ready to start operating, with near zero leakage and minimal product loss.
Start-up condition is governed by hydrostatic principles, since shaft is not turning yet. Spiral groove acts as a step in average clearance between faces. Per FIG. 4, this average clearance is then larger at the grooved area, narrower at the inner non-grooved area and one can then define a ratio of outer to inner clearance. Hydrostatic principle applicable here teaches, that if one then changes this ratio by making spiral grooves deeper or shallower, that means by changing dimension B per FIG. 4, clearance C will change as a consequence. Change will be such, that clearance C will increase with increase in B and vice versa. Similar effect occurs also with spiral grooves, depth of which decreases on the way from outer face periphery inward. The larger the groove depth at the outer periphery and the steeper the groove depth decrease, the larger the equilibrium clearance C and vice versa.
According to this invention, a spiral groove pattern of relatively large dimension A and relatively small dimension B per FIG. 4 will impart a unique hydrostatic property to the seal, where its hydrostatic clearance C will be so small, that it will approach the average clearance due to roughness peaks and valleys on the two sealing surfaces in contact. This situation is shown magnified on FIG. 6 by dimension S. No surface, no mater how smooth, is absolutely flat. It has always certain roughness with miniature peaks and valleys and two such surfaces in contact will always leave passages open to slight fluid flow among contacting roughness peaks. Dimension S shows average clearance due to roughness effect.
Aim of this invention is to design hydrostatic clearance C to approach dimension S in as wide a pressure range as possible, without opening the sealing faces. Then sealing faces will be closed, but with opening and closing forces nearly equal, preventing face friction lock.
Above is demonstrated by chart per FIG. 5, where variations in interface clearance due to pressure change are shown for individual spiral groove patterns as well as for new pattern combination according to this invention.
Chart shows eight curves, two each for three single patterns and additional two for pattern combination. One of the curves coincides with vertical axis and another two curves coincide with each other, so only six curves are plotted in FIG. 5. Spiral groove patterns, corresponding to these curves are shown in cross-section at the upper right side of FIG. 5 together with dimensional information.
First there is a spiral groove pattern A of 3 inch groove diameter and 0.00001 inch groove depth, designed for hydrostatic lift. Its clearance-pressure characteristic at zero speed is shown by curve A1. Its character is such, that already at 40 psig of pressure, there is slight clearance present between the sealing faces. Clearance is calculated and actual seal faces will exhibit some surface roughness, where subject clearance will not necessarily be large enough to eliminate face contact. Yet it will be sufficient to bring approximate equivalence between closing and opening forces, preventing sealing face lock and danger of seal damage. In fact, hydrostatic lift per spiral groove pattern A represents ideal conditions of light face contact, therefore just trace leakage of fluid among face roughness asperities, leakage which does not change much, whether face contact is light or heavy. Seal faces are on the verge of opening at wide range of pressures and shaft rotation can start at any of these pressures without danger of seal damage. Increase in depth of pattern A would lift faces apart, causing significant leakage, an undesirable situation for equipment, that may be on standby under pressure for long periods of time.
It should be noted, that pattern A does not have to be in shape of a spiral to be effective. Per FIG. 7, which is a view similar to FIG. 2, it would be also hydrostatically effective as a pattern of shallow radial grooves 25 at deeper outer spiral grooves 22. Radial grooves 25 result, if spiral angle of groove 24 per FIG. 2 increases. Groove shapes between these two extremes are also effective and, under some circumstances, the shallow grooves 24 of FIG. 2 may be angled in the opposite circumferential direction relative to the deep grooves 22.
Corresponding full speed characteristic for subject pattern A is shown at A2. Dynamics of high speed shaft rotation dictate certain minimal clearances for non-contacting seal operation and clearances as per A2 would not be sufficient. Pattern A alone is therefore not acceptable.
Pattern B of 3.42 inch groove diameter and 0.0002 inch groove depth on the other hand is designed for optimum full speed operation. As such, it is relatively deep for it to pump enough fluid into the seal interface to separate faces sufficiently, relatively short to provide minimal possible hydrostatic effect to prevent it from interfering with any other pattern, with which it may be potentially combined. Pattern B will not lift the faces hydrostatically, therefore its B1 curve coincides with vertical chart axis for zero clearance at all pressures. Such pattern would cause face lock at most pressures, therefore pattern B alone would also be unacceptable. Characteristic B2 shows sufficient seal face clearance for hydrodynamic non-contacting operation.
Third pattern is according to this invention, identified as AB and consists of pattern A, combined with pattern B. Static lift curve AB1 shifts to the right of A1 due to slight remaining effect of B-part of the pattern. Hydrodynamic lift curve AB2 almost coincides with curve B2 since AB2 clearances exceed B2 clearance by rather small margin of less than 5%. This pattern therefore satisfies both criteria of hydrostatic lift for no face lock and satisfactory hydrodynamic clearance for low leakage and represents therefore an improvement over prior art.
For comparison purposes, single pattern C with 3.188 inch groove diameter and 0.0002 inch groove depth of prior art for both hydrostatic lift and hydrodynamic operation is shown with dash lines C1 and C2. Pattern C was designed to lift faces of the seal hydrostatically just enough to assure start-ups at full pressure. An effort to further shorten this pattern for less leakage would result in hydrostatic face lock. It is to be noted here, how relatively unsuitable is deep hydrodynamic groove for hydrostatic lift. As C1 curve shows, seal faces tend to open only at high pressures, yet on opening quickly develop clearance. Need to extend the pattern length to remove face lock considerably penalizes hydrodynamic operation and shifts C2 curve significantly to the right of curves B2 and AB2.
Since leakage would change roughly with third power of clearance, increase in leakage from B2/AB2 to C2 at 1,000 psig means increase from about 0.9 SCFM to about 2.4 SCFM, which is by almost 170%.
As can be seen, AB double pattern per this invention provides for significant savings in leakage, when compared to prior art pattern C. Single pattern B of similar hydrodynamic behavior to AB cannot be used, since it does not provide enough hydrostatic lift and would lock faces. Single pattern A also cannot be used, since it only present face lock, but would not assure non-contacting operation at full pressure, full speed.
In the improved double pattern of this invention, the radially outer deep grooves 22 may have a maximum depth of 0.001 inch, although a more practical maximum depth for the deep grooves 22 is 0.0005 inch, and the preferred depth of the deep grooves 22 is in the range of from about 0.0001 to about 0.0003 inch. As to the shallow grooves, they have a depth which is preferably in the range of from about 0.00001 to about 0.0001 inch, with the depth of the shallow grooves preferably being no more than 0.5 times the depth of the deep grooves, with the shallow grooves preferably having a depth in the range of between about 0.05 and about 0.25 times the depth of the deep grooves.
While the invention as described above provides two sets of grooves of different depths, it will be appreciated that this invention can be extrapolated to provide additional groove sets, such as three groove sets, all of different depths so as to further improve and refine the combination of hydrostatic and hydrodynamic properties provided by the seal.
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.
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Non-contacting spiral groove face seal for shafts rotating at high pressures and high speeds with combination of two groove patterns on one of the two sealing faces of mating sealing rings; one pattern relatively deep, the other relatively shallow. The relatively deep spiral-shaped groove pattern is optimized for hydrodynamic operation and on shaft rotation pumps the sealed fluid in-between sealing faces to set the running clearance. The relatively shallow pattern is designed to prevent a friction lock of the sealing faces hydrostatically at starts and stops of shaft rotation by admitting controlled amount of the sealed fluid between the sealing faces when the shaft is at or near to a stationary condition.
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FIELD OF THE INVENTION
[0001] The present invention relates to cooperative threaded engagement elements with self-locking threads. More particularly, it relates to a pair of threaded engagement elements, one of which has a portion with differing thread parameters, which prevents one element of the pair from loosening relative to the other after tightening.
BACKGROUND OF THE INVENTION
[0002] Bolted joints are used to affix two or more parts together and typically have two engaging elements (a bolt and nut or equivalent structure) that are characterized by cooperative threads. The threads are most often spiral and have a given pitch and thread count. Relative longitudinal movement between the nut and bolt along a common axis is produced when one or the other element is rotated. At some longitudinal position, the two elements engage the parts that are to be fastened, and fix the same in place when sufficient torque is applied to one element relative to the other. The parts remain fixed due to the frictional force that is generated at the interfaces between threads, the parts and the surfaces of the engaging elements (nut and bolt) that contact the parts. This type of fastened joint suffers from the problem of unintentional loosening due to operational conditions. Tightened bolts or nuts rotate loose when relative motion between the cooperating threads occurs.
[0003] Several factors can cause this relative motion. First, parts can bend which results in forces being induced at the friction surface. Second, changes in temperature can cause the bolt and nut to alternatively constrict and expand, causing slight relative movement that reduces those frictional forces. Finally, applied forces on the joint components can lead to shifting of the joint surfaces.
[0004] Many attempts have been made to prevent a bolt from being loosened unintentionally. Some attempts involve the increase of friction between the male and female threads. Other attempts try to increase the frictional force between the bottom of the bolt head and the work piece by the use of extra components such as washers interposed between an engaging element and the part that it contacts. These can be split, star or spring washers. Others have added a chemical adhesive to the threads to bond the nut to the bolt at the threads.
[0005] However, these attempts have several disadvantages. First, these attempts still suffer from relative loosening when different forces are applied. Second, an increase in friction often takes more torque to install than a standard nut and bolt. Third, the extra parts or chemicals significantly increase assembly cost and time. The present invention overcomes these disadvantages by providing a bolt that is as easy to install as a standard assembly but does not suffer from loosening over time.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a threaded element with threads that self-lock when engaged with a cooperatively configured second threaded element.
[0007] Another object of the present invention is to prevent relative loosening between cooperative threads of first and second fastening elements.
[0008] Still another object of the present invention is to shorten the cost and assembly time of a bolted joint.
[0009] According to one aspect of the present invention, a threaded engagement element includes a body having a longitudinal axis and a thread adapted to be received by a corresponding thread of a second element. The threads are characterized by a thread parameter. The element body has first and second portions each with a different value of the thread parameter.
[0010] According to another aspect of the present invention, a cooperative element pair for use in affixing a first part to a second part includes a first element having a longitudinal axis and a thread formed on a surface thereof. A second element has a thread formed in a surface thereof. The thread of the second element is adapted to be received by the first element thread. Each of the first and second element threads are characterized by a thread parameter. The first element further has first and second portions, each with a different value of the thread parameter.
[0011] According to still another aspect of the present invention, a bolt includes a generally cylindrical body having a longitudinal axis and an external thread. The bolt also has a head continuous with the body. In addition, the thread on the body may have more than one thread geometry. Preferably, the thread geometry may be steeper as it becomes closer to the head of the bolt. More preferably, the thread geometry may be steeper for the last four threads closest to the head of the bolt.
[0012] The body may also have more than one thread count. Preferably, the thread count may be higher closer to the head of the bolt. More preferably, the thread count may be higher for the last four threads closest to the head of the bolt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a simplified schematic side view of a bolt with self-locking threads provided in accordance with the present invention.
[0014] FIG. 2 is a simplified schematic end view of the bolt of FIG. 1 .
[0015] FIG. 3 is a simplified schematic illustration of the bolt of FIG. 1 .
[0016] FIG. 4 is a simplified schematic illustration of a second element configured to be received by the bolt of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The present invention is directed to fastening elements that are configured to prevent unintentional loosening. FIG. 1 shows one embodiment of the present invention in a simplified schematic form. In FIG. 1 , a bolt 10 has a generally cylindrical body 12 having a longitudinal axis 14 and an external thread 16 . The bolt 10 also has a head 18 continuous with the body 12 . As seen in FIGS. 2 and 3 , the head 18 has a series of flat peripheral surfaces configured to receive cooperative surfaces of a tool (not shown) that is used to rotate the bolt about the longitudinal axis 14 . The head 18 extends radially beyond the body 12 by a pre-selected amount.
[0018] The body 12 has an external thread 16 all the way to the head 18 , or the body 12 may have a shank 20 disposed between the threaded body and the head 18 . The shank 20 does not have any threads in the preferred embodiment. The longitudinal dimension of the shank is important as detailed hereinafter.
[0019] The threads in both the first and second elements are characterized by certain thread parameters such as pitch, thread count, and thread geometry. “Thread geometry” includes the thread angle, which is the angle of an individual thread as measured from a thread trough 21 to an outer thread surface 23 when compared to a perpendicular 25 extending from longitudinal axis 14 . Thread count is the number of threads per unit of longitudinal measure (e.g. “threads per inch”). “Pitch” is the distance from one thread to the next as measured along the length of the axis. Other thread parameters may also be configured as thread count, pitch, and thread geometry are described herein alone or in combination and are therefore contemplated by the present invention.
[0020] A cooperative threaded engagement element pair includes first and second elements such as a bolt and a nut shown schematically in FIG. 4 . In the prior art, these elements are characterized by uniform thread pitch and thread count allowing for smooth advancement of one element relative to the other until the parts that are to be joined are in fixed contact with one another. As noted, this arrangement often requires additional measures to preclude loosening of the joined parts by way of slight rotational movement.
[0021] With the present invention, the external thread 16 may have more than one thread geometry or more than one thread count. There are at least two regions of the threaded body. The first threaded body portion 28 has a pre-selected thread geometry and count. The second threaded body portion 30 is located adjacent the shank 20 and has a second pre-selected thread count or thread geometry, one (or both) of which is (are) different from that of the first threaded body portion.
[0022] Preferably, the thread geometry becomes steeper closer to the head 18 of the bolt 10 . More preferably, the thread geometry is steeper for the last four threads closest to the shank 20 of the bolt 10 . By “steeper” it is meant that the thread angle increases in magnitude. A change in thread angle of about 10 per cent is preferable.
[0023] In certain applications, it is preferable for the thread count of threaded body portion 30 to become higher closer to the shank 20 . More preferably, the thread count is higher for the last four threads closest to the head 18 of the bolt 10 . In the embodiment of the present invention shown in FIG. 1 , the thread count is increased in threaded body region 30 by about 10% as compared to that of body region 28 .
[0024] In some applications it may be desirable for the threaded body portion 30 to have more than one thread count and/or more than one thread geometry, with a multitude of combinations of the same all contemplated by the present invention. The thread may have both a steeper thread angle and a higher thread count closer to the head 18 of the bolt 10 . In the preferred embodiment, the thread of threaded body portion 30 has a longitudinal dimension that extends to encompass at least the last four threads closest to the head 18 of the bolt 10 . Those skilled in the art will note that the longitudinal dimension of threaded body portion 30 is a function of the particular application.
[0025] In the preferred embodiment, the thread geometry and count of the corresponding thread 42 of the second element 40 that receives that element of the complimentary pair having threaded body portion 30 is the same as that of threaded body portion 28 . However, those skilled in the art will note that the present invention contemplates embodiments wherein the thread geometry and thread count of the corresponding thread 42 of the second element 40 may contain a portion in which either thread geometry or count is varied as well as that in first element threaded body portion 30 .
[0026] In the embodiment of FIG. 1 , the bolt 10 may be used by fitting it into a threaded nut, bore, or hole, any of which comprises the second element 40 of the complimentary element pair. The bolt 10 is then twisted until the corresponding threads 42 of the nut, bore, or hole engage the differing thread geometry or thread count of the external thread 16 . Preferably, the bolt 10 is twisted until the threads 42 of the nut, bore, or hole engage the external thread 16 at a point where the thread angle is steeper or the thread count is higher. More preferably, the bolt 10 is twisted until the threads 42 of the nut, bore, or hole engage the external thread 16 at the last four threads closest to the head 18 of the bolt 10 , where the thread angle is steeper or the thread count is higher. As stated above, the external thread 16 of bolt 10 may have both a steeper thread angle and a higher thread count.
[0027] Those skilled in the art will note that the location of threaded body portion 30 is preferably adjacent the shank whose longitudinal dimension is a function of the particular application. In that sense, the thickness of the parts to be joined are taken into consideration so that the segment of threaded body portion 30 that is engaged with the second element 40 is sufficient to ensure the two elements remain tightly affixed to one another. Furthermore, the present invention also contemplates embodiments where the thread count or geometry of the threaded body portion 30 can decrease as compared to threaded portion 28 .
[0028] Those skilled in the art will note that the cooperative threaded engagement element pair provided in accordance with the present invention is configured to be reusable in that the elements thereof can be repeatedly engaged and disengaged with the benefits of the present invention and without performance degradation. As such it is seen that the present invention overcomes the limitation of the prior art in requiring an additional component such as a split washer or a bonding agent to be applied each and every time the element pair are used to fasten parts together.
[0029] Moreover, the prior art teaches away from the present invention in that it was believed that differences in thread geometry and/or thread count between threaded fastening elements was to be avoided as the threads were inevitably damaged when engaged, thereby precluding proper fastening torque and subsequent reuse. However, the present invention overcomes these drawbacks.
[0030] While the invention has been described with reference to the preferred embodiments, it will be understood by those skilled in the art that various obvious changes may be made, and equivalents may be substituted for elements thereof, without departing from the essential scope of the present invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention includes all embodiments falling within the scope of the appended claims.
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A threaded engagement element comprising a body having a longitudinal axis and a thread adapted to be received by a corresponding thread of a second element. The threads are characterized by a thread parameter. The body has first and second portions that each has a different value for the thread parameter. The body may have more than one thread count or more than one geometry. This configuration creates a threaded engagement element with self-locking threads, which prevents unintentional loosening.
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TECHNICAL FIELD
[0001] The invention relates to shaft speed sensing for various applications such as wind turbine monitoring.
BACKGROUND OF THE INVENTION
[0002] Wind turbines are machines used to convert wind power to electrical power. Often, wind turbines use propellers or turbine blades to drive a gearbox, rotor shaft, and a generator (or other mechanical elements) that ultimately produces electricity. After a period of operation, the mechanical elements used by wind turbines may need to be monitored for abnormal behavior, predictive maintenance, or warranty checks. Condition monitoring (CM) equipment can be installed that provides feedback about the operational condition of the wind turbines. However, linking CM equipment to wind turbines can be a labor-intensive task that involves equipment having a wide range of components. This equipment can typically include a processor, non-volatile memory, as well as various sensors that are coupled to the wind turbine or specific components thereof. These sensors can include a speed sensor for measuring turbine speed, accelerometers for measuring vibration, and a current monitor for determining turbine load.
SUMMARY
[0003] A method of measuring a rotational speed of a shaft is provided, which includes coupling an optical pick-up to a shaft speed sensor having an indicator light that pulses proportionally to a rotational speed of a shaft being measured by the speed sensor, receiving light pulses from the indicator light, and determining the rotational speed based on a rate of received light pulses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Preferred exemplary embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements, and wherein:
[0005] FIG. 1 is a photo depicting portions of a wind turbine and diagrammatically depicts the internal wind turbine shaft in broken lines;
[0006] FIG. 2 is a diagram showing an internal speed sensor and CM equipment including an optical pickup and interface circuit for monitoring pulses of an indicator LED of the speed sensor;
[0007] FIG. 3 depicts examples of speed sensors; and
[0008] FIG. 4 is a block diagram of the interface circuit of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] Although the present invention can be utilized in conjunction with a wide variety of machines to detect rotational speed of a shaft or other element, one exemplary embodiment is described below as it would be used as a part of condition monitoring (CM) equipment for wind turbines.
[0010] A section of one wind turbine design is generally shown at in FIG. 1 . The wind turbine includes a drive shaft 12 that carries turbine blades 14 . The drive shaft 12 connects at one end to a generator (not shown). As wind acts on the blades 14 , the shaft 12 rotates powering the generator and creating electricity. Referring now also to FIG. 2 , the wind turbine includes a wind turbine speed sensor 16 that monitors the speed of the drive shaft 12 as part of wind turbine operation. This sensor 16 is an existing sensor onboard the wind turbine and is not a part of the CM equipment itself which will be described below. The speed sensor 16 can be of the type that includes at least one light-emitting diode (LED) 18 that outputs light pulses with a frequency equal or proportional to the rotational speed of the drive shaft 12 .
[0011] The CM equipment 10 can be temporarily or permanently installed on the wind turbine to gather data about the turbine over a period of time. For temporary installations, the equipment is installed for a period of time and then removed by a technician. As shown in FIG. 2 , the CM equipment 10 includes a processor, digital memory (e.g., ROM, RAM, NVRAM, etc.), a plurality of accelerometers, an optical pickup 20 , and a sensor interface 22 for the optical pickup. Other components can be included as well; for example, a generator current monitor. As will be appreciated by those skilled in the art, the processor, memory, and accelerometers can all be hardware components that are commercially available and can be interconnected and controlled via software to obtain vibration and other such acceleration data from various points or components on the wind turbine. When installing the CM equipment 10 , the optical sensor 20 is located adjacent the LED indicator 18 such that it can detect light pulses emitted from the LED and communicate that information to the processor (CPU). This can be done by clipping the optical sensor 20 onto the speed sensor 16 or otherwise mounting it in sufficiently close proximity to detect the LED light pusles.
[0012] As is known, the speed sensor 16 sends an electronic signal each time the drive shaft 12 rotates a predetermined distance. In one embodiment, the speed sensor 16 is an inductive type that is used in combination with one or more magnetic or ferromagnetic features on the shaft 12 to detect incremental rotation of the shaft. For example, the drive shaft 12 can include a plurality of ferrous teeth (not shown) that encircle the shaft. The ferrous tooth/teeth can be bumps or locations on the drive shaft 12 that have an increased amount of material relative to the area(s) next to the tooth. Each tooth is an equally-spaced and predetermined distance from the nearest tooth. As the drive shaft 12 rotates about an axis 22 , the teeth rotate as well. The speed sensor 16 generates and monitors an inductive magnetic field which is influenced by the passing teeth in a detectable way so that the speed sensor provides an output signal indicative of shaft rotation. By knowing the amount of distance between the teeth (or the number of teeth circumscribing the shaft) and the amount of time passed between sensing the presence of teeth, the wind turbine circuitry can determine the rotational speed of the shaft 12 . This data is used by the wind turbine generator in a manner known in the art.
[0013] The speed sensor 16 also uses the detected inductive pulses to pulse the LED indicator 18 . Since the optical pickup 20 is positioned to detect the light pulses emitted by the LED, then each time the speed sensor 16 activates the LED 18 , the optical pickup 20 detects this and generates a signal of its own. This signal is filtered, amplified, and conditioned by the interface circuit 22 to provide a pulse train having a pulse repetition rate that is indicative of shaft speed. Thus, based on the pulse rate, the CM equipment processor can determine and record the rotational speed of shaft 12 . As shown in FIG. 2 , the pickup can be mounted in close proximity to the LED 18 in such a way to accurately receive the light emitted from the LED. Turning to FIG. 3 , examples of speed sensors 16 are shown. As noted above and shown in FIG. 3 , the speed sensor 16 can be, for example, an inductive type that includes an M12 connector and a plurality of LEDs 18 located on the exterior of the sensor 16 . Alternatively, a glass fiber optic sensor or convergent-mode sensor can be used as shown in FIG. 3 . These also include an indicating LED (not shown). Or, any other suitable sensor can be used that provides a detectable optical output that pulses at a rate dependent on the rotational speed of shaft 12 .
[0014] FIG. 4 depicts the a block diagram of the interface circuit 22 . As shown, the optical pickup 20 can be implemented using a photo diode that changes its conduction characteristic based on received light. The interface circuit 22 includes a signal output that goes to the remainder of the CM equipment 10 for use in condition monitoring of the wind turbine. It also includes an auxiliary output that can be used for other purposes, such as to provide remote real-time monitoring of the turbine speed via cellular or other wireless communication.
[0015] By incorporating an optical pickup in sight of the LED indicator of the speed sensor, the CM equipment can monitor turbine shaft speed without any physical interconnection to the shaft and without the provision of any special additional features to the shaft itself. This can help reduce the cost of the CM equipment and can help expedite the installation and removal of the CM equipment. Monitoring of the speed sensor indicator LED by the optical pickup also allows for diagnosis of problems with the wind turbine speed sensor.
[0016] It is to be understood that the foregoing description is not a definition of the invention, but is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. For example, any suitable shaft speed sensor can be used as long as it provides an optical indication of the shaft rotational speed that can be detected by the optical pickup. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.
[0017] As used in this specification and claims, the terms “for example,” “for instance,” and “such as,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.
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The invention relates to a method of measuring rotational speed of a shaft, comprising the steps of: coupling an optical pickup to a shaft speed sensor having an indicator light that pulses proportionally to rotational speed of a shaft being measured by the speed sensor; receiving light pulses from the indicator light of the speed sensor; and determining the rotational speed based on the rate of received light pulses. Furthermore, the invention discloses a condition monitoring equipment for a wind turbine using the above measuring method.
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FIELD OF THE INVENTION
This invention relates to a textile treatment composition comprising a olyhydroxyalkylurea crosslinking agent having at least two urea moieties.
BACKGROUND OF THE INVENTION
The use of thermosetting resins or reactants to impart crease resistance and dimensional stability to textile materials is known in the art. These materials, known as “aminoplast resins”, include the products of the reaction of formaldehyde with such compounds as urea, thiourea, ethylene urea, dihydroxyethylene urea, melamines or the like. A serious drawback to the use of such materials is that they contain free formaldehyde. This is present during the preparation and storage of the finishing agent and its use in treating textiles, on the treated fabric, and on the finished garments. Also, when the fabrics or garments made therefrom are stored under humid conditions, additional free formaldehyde is produced.
Treating textiles with resin compositions that do not contain or evolve formaldehyde is also known, as in U.S. Pat. No. 3,260,565 which describes finishing agents formed by the reaction of alkyl or aryl ureas or thioureas with glyoxal. U.S. Pat. Nos. 4,332,586 and 4,300,898 describe alkylated glyoxal/cyclic urea condensates as crosslinking agents for textiles. U.S. Pat. No. 4,295,846 describes a finishing agent for textiles which is prepared by reacting urea or symmetrically disubstituted ureas in an aqueous solution with glyoxal. Japanese publication No. 5 3044-567 describes finishing agents formed by the reaction of ethylene urea with glyoxal. These agents, however, have the disadvantage of having marginal anti-wrinkling properties.
U.S. Pat. No. 5,879,749 describes fabric treating compositions that contain a polymer having at least two carboxyl groups and a poly(hydroxy) crosslinking agent. U.S. Pat. No. 5,965,466 describes a method for imparting permanent press properties to a textile comprising applying a (hydroxyalkyl)urea or β-hydroxyalkylamide crosslinking agent to the textile.
The present invention provides a textile treatment composition which imparts anti-wrinkling properties to textiles treated therewith, said textile treatment composition comprising a polyhydroxyalkylurea crosslinking agent having at least two urea moieties which is selected from the group consisting of Structures I-III, respectively, as follows:
wherein A is independently selected from the group consisting of a C 2 to C 36 aliphatic group, a C 6 to C 40 alkaryl group; m is from 1 to 100; n is from 2 to 10; x is from 2 to 100; Z is selected from the group consisting of a diamine, triamine, diol and triol;
R 2 is independently selected from hydrogen or R 5 ; R 5 is independently selected from the group consisting of hydrogen,
and C 1 -C 4 alkyl; R 6 is selected from the group consisting of
and C 1 -C 4 alkyl; R 7 is selected from the group consisting of
and C 1 -C 4 alkyl; R 8 , R 9 and R 10 are independently selected from the group consisting of hydrogen, methyl and ethyl.
According to another aspect the invention provides a textile treatment composition which imparts anti-wrinkling properties to textiles treated therewith, said textile treatment composition comprising the polyhydroxyalkylurea crosslinking agent and a polymer having at least two functional groups selected from the group consisting of carboxyl, anhydride, amine and combinations thereof.
Textiles treated with the compositions of the present invention display a significant reduction in wrinkles compared with nontreated textiles. Moreover, the treated textiles have a tactile sensation of feeling soft and retain their smoothness after laundering.
DESCRIPTION OF THE INVENTION
This invention relates to a textile treatment composition which imparts anti-wrinkling properties to textiles treated therewith. As used herein, “anti-wrinkling” is synonymous with wrinkle resistance, durable press, permanent press, dimensional stability, shrinkage resistance, and wrinkle recovery. The polyhydroxyalkylurea crosslinking agent is essentially free of formaldehyde and may be applied in the form of an aqueous solution or neat.
The textile may be woven or non-woven fabrics and includes, for example, polyester, cotton, rayon, and linen, as well as blends, for example, polyester/cotton or polyester/rayon. Both white and colored (printed, dyed, yarn-dyed, cross-dyed, etc.) fabrics can be effectively treated with the crosslinking agents of the invention. The textiles may comprise new or used clothing including previously worn clothing and/or laundered clothing.
The polyhydroxyalkylurea crosslinking agent has at least two urea moieties. The polyhydroxyalkylurea crosslinking agent is represented by Structures I-III as follows:
In Structures I-III, A is selected from the group consisting of a C 2 to C 36 , preferably a C 2 to C 13 aliphatic group, a C 6 to C 20 , preferably a C 6 to C 15 aromatic group, and a C 6 to C 40 , preferably a C 6 to C 20 alkaryl group; Z is selected from the group consisting of a diamine, triamine, diol, and triol, preferably Z is a diol; m is from 1 to 100, preferably from 1 to 10; n is from 2 to 10, preferably from 2 to 4; x is from 2 to 100, preferably from 2-10;
R 2 is independently selected from hydrogen or R 5 ; R 5 is independently selected from the group consisting of hydrogen,
and C 1 -C 4 alkyl; R 6 is selected from the group consisting of
and C 1 -C 4 alkyl; R 7 is selected from the group consisting of
and C 1 -C 4 alkyl; and R 8 , R 9 , and R 10 are independently selected from the group consisting of hydrogen, methyl and ethyl. A combination of polyhydroxyalkylurea crosslinking agents may be used in the textile treatment composition.
In one embodiment, the polyhydroxyalkylurea represented by Structure I is prepared by polymerizing ethylenically unsaturated monomers having at least one isocyanate moiety to form a polymer which is reacted with an alkanolamine.
In another embodiment, the polyhydroxyalkylurea represented by Structure I is prepared by reacting ethylenically unsaturated monomers containing at least one isocyanate moiety with an alkanolamine followed by polymerization of the monomers.
In one embodiment, the polyhydroxyalkylurea represented by Structure II is prepared by reacting an isocyanate monomer having at least two isocyanate moieties with an alkanolamine.
In one embodiment, the polyhydroxyalkylurea represented by Structure III is prepared by reacting a compound having at least two hydroxy or amine groups with an excess of a isocyanate monomer having at least two isocyanate moieties, to form a polyurethane prepolymer having terminal isocyanate moieties. The polyurethane prepolymer is reacted with an alkanolamine.
Examples of alkanolamines include 2-aminoethanol, 2,2′-iminobisethanol, 2,2′,2″-nitrilotrisethanol, 1-amino-2-propanol, 1,1′-iminodi-2-propanol, 1,1′,1″- nitrilotris-2-propanol, 1-amino-2-butanol, 1,1′-iminodi-2-butanol, 1,1′,1″-nitrilotris-2-butanol, 2-dimethylaminoethanol, 2-diethylaminoethanol, 2-(2-aminoethylamino)ethanol, 2-methylaminoethanol, 2-butylaminoethanol, N-2-hydroxyethylacetamide, 2-anilinoethanol, 2-dibutylaminoethanol, 2-diisopropylaminoethanol, 2-N-ethylanilinoethanol, 2,2′-(methylimino)diethanol, 2,2′-(ethylimino)diethanol, 2,2′-(phenylimino)diethanol, 1-dimethylamino-2-propanol, and 1-(2-aminoethylamino)-2-propanol. Preferably the alkanolamnine is diethanolamine. A combination of alkanolamines can also be used.
The isocyanate monomer having at least two isocyanate moieties may be aromatic or aliphatic. Examples of polyisocyanates include methylene-diphenyl diisocyanate, methylene-bis(4-cyclohexyl-isocyanate), isophorone diisocyanate, toluene diisocyanate, 1,5-naphthalene diisocyanate, 4,4′diphenyl-methane diisocyanate, 2,2′-dimethyl-4,4′-diphenyl-methane diisocyanate, 4,4′-dibenzyl-diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, 2,6- and 2,4-tolylene diisocyanate, xylene diisocyanate, 2,2′-dichloro-4,4′-diisocyanatodiphenylmethane, 2,4-dibromo-1,5-diisocyanatonaphthalene, butane-1,4-diisocyanate, hexane-1,6-diisocyanate, dimer acid diisocyanate (DDI), and cyclohexane-1,4-diisocyanate. A preferred polyisocyanate is hexamethylene diisocyanate. A combination of polyisocyanates may also be used.
The compound having at least two hydroxy or amine groups includes, for example, polyether diols, polyether/polyester diols, polyester diols, polyacetal diols, polyamide diols, polyester/polyamide diols, poly(alkylene ether)diols, polythioether diols, and polycarbonate diols. Polyethylene glycols containing hydrocarbon radicals can be used such as bisphenol-A ethoxylates. Examples of such bisphenol-A ethoxylates include SYNFAC which is available from the Milliken Chemical Co. and MACOL which is available from BASF Corporation. Additionally, ethylene/oxide/butyleneoxide or ethyleneoxide/butyleneoxide/propyleneoxide copolymers can also be used, for example, the commercially available PLURONICS from BASF Corporation. In addition, a hydroxy terminated polyurethane polyol based upon polyethylene glycol or an alkoxy based amine such as JEFFAMINE diamine or triamine, which have terminal amine groups, available from Hunstman, may also be used. JEFFAMINE is a trade name of Huntsman Corporation.
Examples of polyether diols include the condensation products of ethylene oxide, propylene oxide, butylene oxide, or tetrahydrofuran, and their copolymerization, graft or block polymerization products, such as mixed ethylene oxide, propylene oxide, condensates, and the graft polymerization products of the reaction of olefins under high pressure with alkylene oxide condensates.
Suitable polyester diols, polyester amide diols, and polyamide diols are preferably saturated, and are obtained, for example, from the reaction of saturated or unsaturated polycarboxylic acids with saturated or unsaturated polyhydric alcohols. Examples of carboxylic acids include adipic acid, succinic acid, phthalic acid, terephthalic acid, and maleic acid. Examples of compounds having at least two hydroxy or amine groups are ethylene glycol, 1,2-propylene glycol, 1,4-butanediol, neopentyl glycol, hexanediol, trimethylolpropane, ethanolamine, ethylene diamine, and hexamethylene diamine.
Suitable polyacetals can be prepared, for example, from 1,4-butanediol or hexanediol and formaldehyde. Suitable polythioether diols can be prepared, for example, by the condensation of thiodiglycol with ethylene oxide, propylene oxide, butylene oxide or tetrahydrofuran. The preferred polyols are trimethylol propane, 2-ethyl-2-(hydroxymethyl)-1,3-propanediol, pentaerythritol, glycerol and sorbitol.
An aqueous solution containing the crosslinking agent preferably has a pH of from about 1 to about 10, more preferably from about 2 to about 7. Most preferably, the aqueous solution containing the crosslinking agent has a pH of from about 3 to about 5. It is understood that any means of adjusting the pH of the aqueous solution may be employed in the method of the invention to achieve a desired pH.
In one embodiment of the invention, the textile treatment composition contains the polyhydroxyalkylurea crosslinking agent and a polymer having at least two functional groups selected from carboxyl, anhydride, amine and combinations thereof, wherein the polymer is not a polyhydroxyalkylurea crosslinking agent. Preferably, the polymer has at least two carboxyl groups. The polymer is prepared from monomers such as ethylene, vinyl acetate, methacrylic acid, acrylic acid, C 1 to C 8 alkyl esters of methacrylic or acrylic acid, maleic anhydride, maleic acid, itaconic acid, crotonic acid, carboxy ethyl acrylate, butadiene, styrene, and combinations thereof. A preferred polymer is polyacrylic acid.
Optionally, the method of the invention includes a catalyst to speed up the reaction between the crosslinking agents and/or the textile. However, the reaction between the crosslinking agents and/or textile does not require a catalyst. While not wishing to be bound by any particular theory, the inventors believe that a catalyst decreases the zeta potential or the amount of negative charge on the textile surface and thus increases the amount of crosslinking agent which is deposited on the textile or fabric. Any substance that can accept an electron pair from a base can be used as a catalyst.
Preferably, the catalyst is a Lewis acid catalyst selected from dibutyltindilaurate, iron(III)chloride, scandium(III)trifluoromethanesulfonic acid, boron trifluoride, tin(IV)chloride, Al 2 (SO 4 ) 3 xH 2 O, MgCl 2 .6H 2 O, AlK(SO 4 ) 2 .10H 2 O, and Lewis acids having the formula MX n wherein M is a metal, X is a halogen atom or an inorganic radical, and n is an integer of from 1 to 4, such as BX 3 , AlX 3 , FeX 3 , GaX 3 , SbX 3 , SnX 4 , AsX 5 , ZnX 2 , and HgX 2 . More preferably, the Lewis acid catalyst is selected from Al 2 (SO 4 ) 3 xH 2 O, MgCl 2 .6H 2 O, AlK(SO 4 ) 2 .10H 2 O. A combination of catalysts can also be used in the method of the invention.
Any method of applying the crosslinking agent to the textile is acceptable. Preferably, the textile is impregnated with an aqueous solution of the crosslinking agent. As used herein, “impregnate” refers to the penetration of the solution into the fiber matrix of the textile, and to the distribution of the solution in a preferably substantially uniform manner into and through the interstices in the textile. The solution therefore preferably envelopes, surrounds, and/or impregnates individual fibers substantially through the thickness of the textile as opposed to only forming a surface coating on the textile.
In one embodiment of the invention, the aqueous solution of the crosslinking agent is applied to the textile in a textile manufacturing process as part of the durable press finishing operation.
In one embodiment of the invention, where the textile is not treated in a textile manufacturing process, the crosslinking agent is applied in a laundering process, most preferably to rinse water in the rinse cycle of the laundering process at home or at a laundrymat.
In one embodiment of the invention, the crosslinking agent is added to a laundering process during the wash cycle.
In one embodiment of the invention, the crosslinking agent is applied by soaking the textile in an aqueous solution containing the crosslinking agent.
In one embodiment of the invention, the crosslinking agent is applied by spraying an aqueous solution containing the crosslinking agent on a textile.
In one embodiment of the invention, the crosslinking agent is applied by spraying an aqueous solution containing the crosslinking agent on a textile and then ironing the textile.
The treated textile is cured at room temperature or at the normal temperatures provided by either a drying unit used in a textile manufacturing process such as a steam heated drying cylinder, an oven, or an iron. Drying temperatures generally range from about 20° C. to about 300° C. Such temperatures permit water to be removed, thereby inducing crosslinking, for example, by means of ether linkages, of the polyhydroxyalkylurea crosslinking agent with the textile. One of the advantages of the crosslinkers of the present invention is that they are stable at elevated temperatures and therefore work particularly well in systems which must be cured at temperatures greater than about 90° C.
In the case where a treated textile is dried by means of a dryer unit, oven, or iron, the residence time ranges from about 1 second to about 200 seconds, depending on the temperature. The actual residence time for a particular textile sample depends on the temperature, pressure, type of fabric, and the type and amount of catalyst. Preferably, the time and temperature required to cure the polyhydroxyalkylurea crosslinking agent with the textile ranges from about 2 to about 60 seconds at a textile temperature ranging from about 20° C. to about 250° C. After the textile with the solution of the crosslinking agent applied thereto is dried/cured, subsequent coatings or additives such as starch may be applied.
In a preferred embodiment, a textile treated with the polyhydroxyalkylurea crosslinking agent is ironed both on the inside and outside surfaces to maximize the amount of crosslinking and thus anti-wrinkling properties of the textile.
Preferred means of applying the aqueous solution of the crosslinking agent on a textile manufacturing machine are by puddle press, size press, blade coater, speedsizer, spray applicator, curtain coater and water box. Preferred size press configurations include a flooded nip size press and a metering blade size press.
Preferred means of applying the aqueous solution of the crosslinking agent on off-machine coating equipment in a textile manufacturing process are by rod, gravure roll and air knife. The solution may also be sprayed directly onto the textile or onto rollers which transfer the solution to the textile. In an especially preferred embodiment of the invention, impregnation of the textile with the aqueous solution of the crosslinking agent occurs by means of a puddle size press.
Preferred means of applying the aqueous solution of the crosslinking agent in a laundering process are by adding the solution to the rinse water during the rinse cycle in the laundering process. In an especially preferred embodiment of the invention, impregnation of the textile with the aqueous solution of the crosslinking agent occurs during the final rinse cycle in a laundering process. In an additional especially preferred embodiment of the invention, impregnation of the textile with the aqueous solution of the crosslinking agent occurs in a washing machine which contains at least one textile, the crosslinker and optionally a catalyst, wherein the washing machine is not operating so that the textile remains in contact with the treatment solution for a period of time to facilitate the impregnation of the treatment solution into the textiles. The washing machine is turned on to the spin cycle, the textiles are removed, and dried.
Another preferred means of applying the aqueous solution of the crosslinking agent to a textile such as clothing is spraying by means of a pump or aerosol a solution of the crosslinking agent onto the textile.
The concentration of the polyhydroxyalkylurea crosslinking agent in an aqueous solution is from about 0.001 to about 50 weight percent, preferably 0.01 to 10 weight percent, based on the total weight of the aqueous solution. More preferably, the concentration of the crosslinking agent in an aqueous solution is from 0.1 to 2 weight percent.
The following nonlimiting examples illustrate further aspects of the invention.
EXAMPLE 1
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure I
Polymethylene polyphenylisocyanate, commercially available as PAPI 135, equivalent molecular weight of 133.5 and an average isocyanate functionality of 2.7, was reacted with diethanolamine in a molar ratio of NCO/NH of 1:1.
EXAMPLE 2
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure II
At 23° C., 105 g of diethanolamine was added over 2 hours to a solution of 84 g of hexamethylene diisocyanate in 200 g of acetone. (R 1 and R 2 are ethanol) The temperature increased to approximately 30° C. and the solution became thick and hazy. The reaction was followed by monitoring the disappearance of the isocyanate peak by IR spectroscopy. After 5 hours, the acetone was distilled off to yield a viscous clear liquid.
EXAMPLE 3
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure II
At 23° C., 51.1 g of dimethylaminopropylamine was added over 2 hours to a solution of 84.1 g of hexamethylene diisocyanate in 200 g of acetone. The reaction was stirred for 2 hours and then 52.6 g of diethanolamine was added over 2 hours at room temperature. After 5 hours, the acetone was distilled off to yield a viscous clear liquid.
EXAMPLE 4
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A solution of 150 g of ethyl acetate and 140 g of PEG 8000 (polyethylene glycol having a molecular weight of 8000) was heated to reflux with a nitrogen purge for 30 minutes to remove about 10 mL of ethyl acetate and any residual water. The solution was cooled to 65° C. and 7.7 g of hexamethylene diisocyanate and 0.2 g of dibutyltinlaurate were added. The reaction solution was held at 65° C. for 24 hours while stirring. The temperature was raised to reflux and 5.93 g of diethanolamine (0.0564 moles) was added. After 5 hours, 160 g of water was added and the ethyl acetate was distilled off in about 2 hours.
EXAMPLE 5
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that the PEG 8000 was replaced with PPG 400 (polypropylene glycol having a molecular weight of 400).
EXAMPLE 6
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that the PEG 8000 was replaced with RUCOFLEX S107-110 (neopentyladipate polyol from Ruco Polymer Corporation).
EXAMPLE 7
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that diethanolamine was replaced with ethanolamine.
EXAMPLE 8
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that diethanolamine was replaced with propanolamine.
EXAMPLE 9
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that diethanolamine was replaced with 1,1-dimethylolpropylamine.
EXAMPLE 10
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that hexamethylene diisocyanate was replaced with isophorone diisocyanate.
EXAMPLE 11
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that hexamethylene diisocyanate was replaced with methylene-bis(4-cyclohexylisocyanate).
EXAMPLE 12
Preparation of Polyhydroxyalkylurea Crosslinking Agent Having Structure III
A polyhydroxyalkyl urea was prepared according to the procedure set forth in Example 4, except that hexamethylene diisocyanate was replaced with toluene diisocyanate.
EXAMPLE 13
Cotton swatches, 4″×6.5″ were soaked for 10 minutes in varying concentrations as set forth in Table I of a polyhydroxyalkylurea crosslinking agent prepared in Examples 2 or 3, and MgCl 2 .6H 2 O catalyst in aqueous solution. A control swatch was presoaked with water without the polyhydroxyalkylurea crosslinking agent or catalyst. The swatches were ironed at high heat until dry. The swatches were washed separately in a TERG-O-TOMETER under the following wash conditions: 1L 110 ppm hardness water (2:1 CaCl 2 to MgCl 2 ), 94° C., 0.9 g/l AATCC standard detergent, 10 minute wash, 3 minute rinse. The swatches were squeezed tightly and dried in a commercial clothes dryer using the “normal” setting for 20 minutes. The swatches were laid on a flat surface and the major folds were removed, but no attempt was made to stretch the fabric. The swatches were evaluated for wrinkles on a subjective scale of 1 to 5 wherein 1 signified very few wrinkles and 5 signified a majority of wrinkles. The test results are summarized in Table I.
TABLE I
Permanent Press Finishing on Cotton Swatches.
Polyhydrox-
MgCl 2
Polyhydrox-
yalkylurea
6H 2 O
Visual
Swatch #
yalkylurea
wt. %
wt. %
Rating
Result
Control
None
0
0
5
very
wrinkled
1
Ex. 2
4
2.5
4
less wrinkled
than control
2
Ex. 3
4
2.5
4
less wrinkled
than control
3
Ex. 2
8
5
2
very few
wrinkles
4
Ex. 3
8
5
2
very few
wrinkles
The test results in Table I show that the cotton swatches pretreated with the polyhydroxyalkylurea crosslinking agents of the invention and catalyst were significantly less wrinkled after washing than the control swatch which was not pretreated with the polyhydroxyalkylurea crosslinking agents.
While the invention has been described with particular reference to certain embodiments thereof, it will be understood that changes and modifications may be made by those of ordinary skill in the art within the scope and spirit of the following claims.
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A textile treatment composition which imparts anti-wrinkling properties to textiles treated therewith, said textile treatment composition comprising a polyhydroxyalkylurea crosslinking agent having at least two urea moieties. Textiles treated with the compositions of the invention display a significant reduction in wrinkles compared with nontreated textiles. Moreover, the treated textiles have a tactile sensation of feeling soft and retain their smoothness after laundering.
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CROSS REFERENCE TO RELATED APPLICATION(S)
This application claims priority from U.S. provisional application No. 60/476,314, filed Jun. 6, 2003, which is incorporated by reference as if fully set forth.
FIELD OF THE INVENTION
The present invention generally relates to transmitter design in wireless communication systems. More particularly, the present invention relates to digital signal processing (DSP) techniques used to compensate for the impairments introduced in an analog radio transmitter, such as passband distortion, carrier leakage, amplitude imbalance, phase imbalance or the like.
BACKGROUND
Existing wireless system architectural configurations impose stringent constraints on the system designer with regards to transmitting communication signals. Moreover, such configurations often provide low reliability communication links, high operating costs, and an undesirably low level of integration with other system components.
In the radio frequency (RF) section of a conventional low-cost wireless transmitter configured with analog components, a considerable level of distortion occurs when RF signals are processed. Such distortions include carrier leakage, phase imbalance, amplitude imbalance, or the like. Higher cost components with better distortion characteristics that enhance signal quality may be overlooked during the design phase in order to reduce the cost of the end-product.
Because the costs of components that process RF analog signals are higher than the components that use DSP, it is desired to provide a digital baseband (DBB) system, including a low cost transmitter with low noise and minimal power requirements, that utilizes DSP techniques as much as is practicable.
SUMMARY
In order to compensate for performance degradation caused by inferior low-cost analog radio component tolerances of an analog radio, a wireless communication transmitter employs a control process to implement numerous DSP techniques to compensate for deficiencies of such analog components so that modern specifications may be relaxed. By monitoring temperature, bias current or the like, enhanced phase and amplitude compensation, as well as many other RF parameters may be implemented.
In a preferred embodiment, the present invention is a digital baseband (DBB) transmitter or a wireless transmit/receive unit (WTRU) which includes an analog radio transmitter, a digital pre-distortion compensation module, a digital direct current (DC) offset compensation module, a digital amplitude imbalance compensation module, a digital phase imbalance compensation module, at least one digital to analog converter (DAC) for interfacing the digital compensation modules with the analog radio transmitter, and at least one controller in communication with the analog radio transmitter and each of the digital compensation modules, wherein the digital compensation modules correct RF parameter deficiencies that occur in the analog radio transmitter.
The DBB transmitter may further include a modem for generating in-phase (I) and quadrature (Q) signal components which are input to each of the digital compensation modules, the DAC and the analog radio transmitter.
The DBB transmitter may further include a low pass filter (LPF) coupled to each of the I and Q inputs of the digital pre-distortion compensation module. Each LPF may be a root-raised cosine (RRC) filter.
The analog radio transmitter may include a power amplifier, a modulator, a power detector, a temperature sensor for monitoring a temperature reading associated with the analog radio transmitter, and a bias current sensor for monitoring a bias current reading associated with the analog radio transmitter. At least one of the digital compensation modules may be activated in response to the bias current sensor or the temperature sensor.
The DBB transmitter may further include a memory for storing a plurality of look up tables (LUTs). One of the LUTs may be selected for use by the digital pre-distortion compensation module in response to the temperature reading monitored by the temperature sensor.
The power amplifier may be prone to a linearity deficiency. The digital pre-distortion compensation module may be configured to distort the phase and amplitude of the I and Q signal components based on the input power level of the power amplifier as measured by the power detector, and gain and phase characteristics of the power amplifier stored in the selected LUT, such that the power amplifier generates a linear response rather than a distorted response.
The modulator may be prone to a carrier leakage deficiency. A minimum detected reading associated with each of the signal inputs may be determined. First and second DC offset compensation values are determined based on the minimum detected readings. The digital DC offset compensation module may be configured to eliminate carrier leakage associated with the modulator by adjusting the respective DC levels of the two signal inputs based on the first and second DC offset compensation values. The modulator may have a local oscillator (LO) frequency at which the minimum detected readings are determined.
The modulator may be prone to an amplitude balance deficiency. The digital amplitude imbalance compensation module may be configured to adjust the power level of one of the I and Q signal components, such that the power level of each of the I and Q signal components is the same.
The modulator may be prone to a phase balance deficiency. The digital phase imbalance compensation module may be configured to adjust the phase of the I and Q signal components, such that the phase of each of the I and Q signal components are orthogonal to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed understanding of the invention may be had from the following description of a preferred example, given by way of example and to be understood in conjunction with the accompanying drawing wherein:
FIG. 1 is a block diagram of a transmitter with a DBB compensation processor operating in accordance with the present invention;
FIG. 2 shows the individual digital compensation modules that are included in the DBB compensation processor of FIG. 1 ;
FIG. 3 shows an exemplary configuration of the digital compensation modules of FIG. 2 ;
FIG. 4 is a flow chart of an exemplary control process used to compensate for impairments in the transmitter of FIG. 1 ;
FIG. 5 shows an exemplary configuration of the digital pre-distortion compensation module of FIG. 2 ;
FIG. 6 shows an exemplary configuration of the digital DC offset compensation module of FIG. 2 ;
FIG. 7 shows an exemplary configuration of the digital amplitude imbalance compensation module of FIG. 2 ; and
FIG. 8 shows an exemplary configuration of the digital phase imbalance compensation module of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a DBB transmitter which enables high performance solutions to be shifted from RF to digital baseband by using low performance radio components and compensating in the DBB for the lower radio performance. Thus, the present invention promotes lower cost, lower power consumption and lower hardware complexity. By providing cross optimization between the radio and the DBB, the performance compensation in DBB is tied to the characteristics of the radio that the DBB is integrated with.
Preferably, the DBB transmitter disclosed herein is incorporated into a wireless transmit/receive unit (WTRU). Hereafter, a WTRU includes but is not limited to a user equipment, mobile station, fixed or mobile subscriber unit, pager, or any other type of device capable of operating in a wireless environment. The features of the DBB transmitter may be incorporated into an integrated circuit (IC) or be configured in a circuit comprising a multitude of interconnecting components.
The present invention is applicable to communication systems using time division duplex (TDD), frequency division duplex (FDD), code division multiple access (CDMA), CDMA 2000, time division synchronous CDMA (TDSCDMA), orthogonal frequency division multiplexing (OFDM) or the like.
FIG. 1 is a block diagram of a DBB transmitter 100 . The DBB transmitter 100 includes a modem 105 which outputs digital signals including in-phase (I) and quadrature (Q) signal components 110 , 115 , respectively and passes the digital signals through low pass filters (LPFs) 120 , 125 , DBB compensation processor 130 and digital to analog conversion (DAC) circuit 135 , which outputs analog signals to analog radio transmitter 150 . LPFs 120 , 125 may be root-raised cosine (RRC) filters or other suitable filters. The DAC circuit 135 includes DACs 140 and 145 .
The DBB transmitter 100 further includes a controller 155 which maintains control over the compensation processor 130 and all of the active components of the analog radio transmitter 150 . Furthermore, controller 155 has access to transmit power control (TPC) signals received by the modem 105 from a base station or other entity, whereby calculations or other functions performed by the controller 155 may depend.
The analog radio transmitter 150 includes an antenna 160 , a power amplifier 165 , a modulator 170 , a power detector 175 , a temperature sensor 180 for monitoring the temperature of the analog radio transmitter 150 and a bias current sensor 185 for measuring the bias current of the analog radio transmitter 150 . The components in the analog radio transmitter 150 consist of low cost (i.e., “low-end” quality) components having “relaxed” specifications. For example, the specifications for the power amplifier 165 need not be stringent because of the availability of a pre-distortion compensation module in the DBB compensation processor 130 .
Referring to FIG. 2 , THE DBB compensation processor 130 includes one or more of the following modules used to enhance the performance of the analog radio transmitter 150 :
1) a digital pre-distortion compensation module 205 ; 2) a digital DC offset compensation module 210 ; 3) a digital amplitude imbalance compensation module 215 ; and 4) a digital phase imbalance compensation module 220 .
The digital pre-distortion compensation module 205 is used to correct transmission amplitude characteristics, such as amplitude modulation (AM) to AM and AM to phase modulation (PM) signal characteristics. The amplitude and phase characteristics of the power amplifier 165 in the analog radio transmitter 150 may be determined using a statistical sampling method or it may be based on specifications provided by the manufacturer of the power detector 165 . The digital pre-distortion compensation module 205 estimates the power at the antenna 160 of the analog radio transmitter 150 based on a received signal input and a TPC command received from the modem 105 . Based on known gain and phase characteristics of the power amplifier 165 , the digital pre-distortion compensation module 205 purposely distorts the phase and amplitude of the I and Q signal components, such that the power amplifier 165 generates a linear response, rather than a distorted response. The digital pre-distortion compensation module 205 may refer to a look up table (LUT) or the like to obtain an inverse of such amplifier characteristics. This embodiment of the present invention is advantageous because RF parameter standards such as intermodulation distortion may be met, even though cheap and low quality components (e.g., an amplifier having a low output power rating) are used in the analog radio transmitter 150 .
The digital DC offset compensation module 210 is used to correct, (i.e., suppress), carrier leakage associated with the modulator 170 in the analog radio transmitter 150 by adjusting the DC levels of the I and Q signal components based on previously determined (i.e., stored) first and second DC offset compensation values. To determine the DC offset compensation values, the I and Q signal component inputs 110 , 115 of the DBB transmitter 100 are switched (switch not shown) from the modem 105 to the controller 155 . The controller 155 individually sweeps the DC level of each of the I and Q signal component inputs 110 , 115 (e.g., from minus to plus sequentially or vice versa) while the power detector 175 is used to determine respective first and second minimum detected readings at the local oscillator (LO) frequency of the modulator 170 . The signal component input that is not currently being swept is temporarily disabled (e.g., the controller 155 turns the unswept signal component input off by setting it to zero).
The first and second DC offset compensation values (i.e., compensation factors K 1 and K 2 ) are derived by interpolating the first and second minimum detected readings. The first and second DC offset compensation values are then stored for future reference, whereby the DC levels of the I and Q signal components are adjusted based on the first and second DC offset compensation values, respectively.
In an alternate embodiment, the controller 155 may be used in conjunction with a detection algorithm and the power detector 175 . The controller 155 simultaneously sweeps the DC level of each of the I and Q signal component inputs 110 , 115 . The algorithm determines at least one minimum detected reading by using a coordinate system application, whereby the DC levels of each of the I and Q signal components are applied to an x-axis and y-axis, respectively, while detected readings sensed by the power detector 175 are applied to a z-axis.
The digital amplitude imbalance compensation module 215 is used to balance the I and Q signal components, such that the modulator 170 in the analog radio transmitter 150 modulates the I and Q signal components with equal power levels. Assuming that the modulator 170 is cheap and of low quality, the modulator 170 is prone to an amplitude balance deficiency. For example, if the I signal component is 1.0 dB below the Q signal component, the digital amplitude imbalance compensation module 215 will cause the Q signal power level to be reduced by 1.0 dB. Thus, at the output of modulator 170 , the I and Q signal components will be at the same amplitude. Using controller 155 , the I and Q signal components may be turned on and off on an individual basis. For example, if controller 155 turns off the Q signal component, whereby only the I signal component is sent, the controller 155 can determine what power level the power detector 175 in analog radio transmitter 150 is reading. Assuming that the power level is a desired target level, the I signal component is then turned off and the Q signal component is turned back on. The digital amplitude imbalance compensation module 215 adjusts the power level of the Q signal component such that the power detector reads the same power level (i.e., the desired target level) for both the I and Q signal components.
The modulator 170 in the analog radio transmitter is also prone to a phase balance deficiency. The digital phase imbalance compensation module 220 is used to balance the phase of the I and Q signal components. The I and Q signal components are activated at the same time and then the power level of both of the I and Q signal components is reduced by 3.0 dB, (i.e., cut in half so that the power level measured by the power detector 175 is equal to the target power level when only one of the signal components is activated with orthogonal I and Q). This procedure is used to establish a reference power level, as measured by the power detector 175 . If the difference between the reference power level and the current power level measured by the power sensor 175 is equal to the desired target power level, the I and Q signal components are orthogonal, whereby the real and imaginary parts have a phase difference of 90 degrees to each other. Based on power level readings performed by the power detector 175 of analog radio transmitter 150 , a phase difference of less than 90 degrees between the I and Q signal components will cause the power detector 175 to read a power level greater than the target power level. A phase imbalance of greater than 90 degrees between the I and Q signal components will cause the power detector 175 to read a power level less than the target power level. The phase is adjusted by the digital phase imbalance compensation module 220 in response to a phase error derived from the difference between the target power level and the power level read by the power detector 175 .
The digital compensation modules included in the transmitter DBB compensation processor 130 may be designed according to numerous configurations. However, it is noted that the LPFs 120 , 125 , must precede the digital pre-distortion compensation module 205 . FIG. 3 shows a preferred exemplary configuration 300 for the modules of the DBB compensation processor 130 .
FIG. 4 is a flow chart depicting the method steps of an exemplary process 400 used to compensate for impairments in the DBB transmitter 100 . In step 405 , an initialization flag is set to one, indicating that the process 400 has begun. In step 410 , a desired communication mode is selected. The communication mode may be TDD, FDD or any other communication mode, such as TDSCDMA, OFDM, CDMA 200 or the like.
In step 415 , if the TDD mode is selected, the TDD mode is initialized. In step 420 , if the FDD mode is selected, the FDD mode is initialized. In step 425 , if another communication mode is selected, it is initialized. In step 430 , the biasing conditions of the analog radio transmitter 150 are monitored by the bias current sensor 185 , indicating, for example, how much current the power amplifier 165 is drawing.
In step 435 , the temperature of the analog radio transmitter 150 , or a selected component therein, is monitored by the temperature sensor 180 . In step 440 , the initialization flag is read to determine whether the process 400 has completed at least one cycle (i.e., steps 445 , 450 and 455 have been implemented). An initialization flag set to one, as implemented in step 405 , indicates that the process 400 has not completed at least one cycle. If the initialization flag is determined in step 440 to be one, in step 445 the pre-distortion compensation parameters are set up for the digital pre-distortion compensation module 205 by selecting one of a plurality of look up tables (LUTs) from an LUT memory 190 based on the temperature monitored by temperature sensor 180 and/or the bias current as measured by the bias current sensor 185 .
Amplitude or phase changes associated with the power amplifier 165 , as monitored by the power detector 175 or any other parameter that the programmer and/or designer of the DBB transmitter 100 desires to have monitored may be used to select an LUT from the LUT memory 190 . The LUT memory 190 may reside in the digital pre-distortion compensation module 205 , in the controller 155 or in any other desirable location within DBB transmitter 100 .
In step 450 , carrier leakage, (i.e., direct current (DC) levels), on the I and Q signal components is suppressed by the digital DC offset compensation module 210 . In step 455 , amplitude and phase imbalances are compensated by using the digital amplitude imbalance compensation module 215 and the digital phase imbalance compensation module 220 , respectively, as described above.
After the process 400 completes one cycle, by completing step 455 , the initialization flag is set to zero in step 460 and the process returns to step 430 whereby if it is determined in step 465 that there was a significant change in the bias current and/or temperature, the steps 445 , 450 and 455 of compensating various parameters of the analog radio transmitter 150 may be repeated.
Upon powering up the DBB transmitter 100 , it is envisioned that all of the digital compensation modules in DBB compensation processor 130 would be implemented to optimize the parameters of the analog radio transmitter 150 prior to commencing communications. After the commencement of communications, selective ones of the digital compensation modules 205 , 210 , 215 , 220 may be configured to run on a periodic or continuous basis, or in response to a particular event or user request. For example, if the temperature sensor 180 in the analog radio transmitter 150 detects a certain rise in temperature (e.g., five degrees), the activation of one or more of the digital compensation modules 205 , 210 , 215 , 220 may be desired.
FIG. 5 shows an exemplary configuration of the digital pre-distortion compensation module 205 including a power estimation unit 505 , multipliers 510 , 515 , 520 , 525 , 530 , adders 535 , 540 , 545 , 550 , LUT 555 and phase distortion compensation unit 560 . The I and Q signal components are received at power estimation unit 505 which estimates the power using I 2 +Q 2 . The output of the power estimation unit 505 (I 2 +Q 2 ) is multiplied by a transmit power control (TPC) via multiplier 510 , and the resulting product is input into LUT 555 , which provides AM to AM compensation for deficiencies in the analog radio transmitter 150 . The TPC controls the output power of the analog radio transmitter 150 , as designated by the resulting product (I 2 +Q 2 )×TPC. The LUT 555 provides the RF characteristic information associated with the power amplifier 165 and/or other components of the analog radio transmitter 150 such that deficiencies of the amplifier 165 , such as undesired gain compression and/or dynamic range characteristics which cause nonlinearity of the RF output at antenna 160 , may be eliminated. The output of the LUT 555 is multiplied by the I and Q signal components via multipliers 515 and 520 , and the resulting products are added to the I and Q signal components via adders 535 and 540 , respectively. Thus, the amplitude characteristics of the I and Q signal components are altered in accordance with the LUT 555 so as to compensate for distorted amplitude characteristics of the analog radio transmitter 150 .
Referring still to FIG. 5 , the product of (I 2 +Q 2 ) and the TPC is also input into phase distortion compensation unit 560 which provides AM to PM compensation for deficiencies in the analog radio transmitter 150 . The phase distortion compensation unit 560 , operating in conjunction with multipliers 525 , 530 and adders 545 , 550 , adjusts the phase differentiation between the I and Q signal components such that they are orthogonal to each other, (i.e., the real and imaginary signal parts have a phase difference of 90 degrees).
FIG. 6 shows an exemplary configuration of the digital DC offset compensation module 210 including adders 605 and 610 . Compensation factors K 1 and K 2 are added to the I and Q signal components, respectively, such that carrier leakage is eliminated by canceling out undesired DC offsets.
FIG. 7 shows an exemplary configuration of the digital amplitude imbalance compensation module 215 including multiplier 705 and adder 710 . Compensation factor K 1 is multiplied with the Q signal component via multiplier 705 , and the resulting product is then added to the Q component via adder 710 , such that the power level of the Q signal component is adjusted to be the same as the I signal component. Note that the sole purpose of the multiplier 705 is to avoid the unintentional deactivation of the Q signal component should the value of K 1 =0. Alternatively, the configuration of multiplier 705 and adder 710 may be incorporated into the I signal component, or in both of the I and Q signal components.
FIG. 8 shows an exemplary configuration of the digital phase imbalance compensation module 220 including adders 805 , 810 and multipliers 815 , 820 . In response to a phase error 825 which indicates that the I and Q components are not orthogonal to each other, the phase difference between the I and Q components are adjusted accordingly.
While this invention has been particularly shown and described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention described hereinabove.
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In order to compensate for performance degradation caused by inferior low-cost analog radio component tolerances of an analog radio, a wireless communication transmitter employs a control process to implement numerous digital signal processing (DSP) techniques to compensate for deficiencies of such analog components so that modern specifications may be relaxed. By monitoring a plurality of parameters associated with the analog radio, such as temperature, bias current or the like, enhanced phase and amplitude compensation, as well as many other radio frequency (RF) parameters may be implemented.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of and priority to European Patent Application Serial No. EP15305621.3 filed Apr. 23, 2015, the disclosure of the above-identified application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to a package for a surgical mesh.
BACKGROUND OF THE RELATED ART
[0003] Surgical meshes used for wall reinforcement, for example for the abdominal wall, are widely used in surgery. These surgical meshes are intended to treat, for example, hernias by temporarily or permanently filling a tissue defect. These surgical meshes are made generally from a surgical biocompatible textile and can have a number of shapes, for example rectangular, circular or oval, depending on the anatomical structure to which they are to adapt. The surgical mesh is generally flat and may vary in dimensions, from for example 5×10 cm up to 30×50 cm, depending on the size of the defect to be treated.
[0004] Before being packaged as a commercial product and shipped to hospitals or end-users, the surgical mesh has to be sterilized to prevent contamination to the patient body in which it is intended to be implanted.
[0005] Gas sterilization is commonly used in the medical field and surgical meshes are usually sterilized by means of ethylene oxide (EtO) gas.
[0006] The sterilization process generally requires the immersion of the surgical mesh in ethylene oxide for a time sufficient for the gas to sterilize the surgical mesh. For handling purposes, the surgical mesh is usually inserted into a handling pouch before being submitted to the sterilization process.
[0007] The handling pouch is provided with a window made of a material which is impervious to contamination by microorganisms, bacteria and/or a biologically active substance which may come into contact with the pouch while it is being handled, while at the same time remaining permeable to a sterilization gas such as for example ethylene oxide. Such a material is for example a nonwoven made of filaments of a high density polyethylene bound together by heat and pressure, such as a product sold by the Du Pont de Nemours under the trademark “Tyvek®”. The surgical mesh to be sterilized is therefore humidified by exposure to water vapor, inserted into a “Tyvek®” pouch and submitted to ethylene oxide gas for sterilization.
[0008] However, it may happen, in particular for large surgical meshes, that the ethylene oxide gas may not reach the entire surface of the surgical mesh and/or does not diffuse in the surgical mesh a sufficiently efficient manner when the surgical mesh is first packaged in a pouch with a “Tyvek®” window. This proves to be a problem as it is desirable that sterilization is completed to a high degree on the entire surface of the surgical mesh.
[0009] Furthermore, in order to proceed to ethylene oxide sterilization, the surgical mesh must be previously humidified. The larger the mesh, the more humid the mesh will be after the sterilization step. In addition, because of its intrinsic nature, the surgical mesh is subject to moisturization. Moisturization has to be avoided during transportation and storage so as to maintain optimal dry conditions of the surgical mesh at the moment of its use.
SUMMARY OF THE INVENTION
[0010] In this technical context, it would be desirable to provide a packaging for a surgical mesh allowing an efficient ethylene oxide gas sterilization of all surgical meshes, whatever their size, that would prevent humidity of ambient air to permeate through the packaging, and that would also favour drying of the surgical mesh during storage and transportation.
[0011] The present invention relates to a package for a surgical mesh comprising
a receiving member configured and dimensioned to receive a surgical mesh, and a covering member configured and dimensioned to cover the said at least one surgical mesh maintaining with the receiving member the surgical mesh in a substantially flat position, and a gas channelling network interposed between the said receiving member and the said covering member configured to channel a sterilization gas within the surgical mesh.
[0015] Thus, the invention makes it possible to maintain a surgical mesh in a substantially flat position and to bring a sterilizing gas in the entire surface of the mesh. This proves to be a great advantage for large surgical meshes, which tend to be partially sterilised using prior art sterilizing techniques.
[0016] In a embodiment of the invention, the receiving member and the covering member define at least one gas diffusing compartment connected to the said gas channelling network.
[0017] In an embodiment of the invention, the covering member includes at least one cut off portion allowing a large exposure to a sterilizing gas and a large exposure for humidity absorption by a desiccant agent.
[0018] In an embodiment, the receiving member comprises a resting rib and an inner wall configured to receive the at least one surgical mesh and the covering member comprises at least one resting rib and an inner wall configured to maintain the at least one surgical mesh between the said resting ribs and to define the at least one gas diffusing compartment for a sterilizing gas.
[0019] In an embodiment, the receiving member comprises at least one groove and the covering member comprises at least one groove defining with at least one groove of the receiving member a channel for a sterilizing gas.
[0020] In an embodiment, the receiving member and/or the covering member comprise at least one transverse resting ribs forming at least two diffusing compartments.
[0021] In an embodiment, the receiving member and the covering member include peripheral rim provided with at least one locking pin and at least one corresponding locking opening.
[0022] In an embodiment, the peripheral rim includes a series of locking toothing.
[0023] In an embodiment, at least one of the receiving member and of the covering member includes a cavity configured to receive a capsule of desiccant material.
[0024] In an embodiment, the receiving member and the covering member have a substantially rectangular shape.
[0025] In an embodiment, the covering member includes at least two cut off portions.
[0026] In an embodiment, the covering member includes a central portion and two lateral portions extending from the central portion.
[0027] In an embodiment, the covering member includes a hinge allowing access to the surgical mesh.
[0028] In an embodiment, the hinge is formed by a weakened line.
[0029] In an embodiment, the hinge is positioned at the junction the central portion and the lateral portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The foregoing objects and advantages of the present invention will become apparent from the reading of the following description in connection with the accompanying drawings, in which:
[0031] FIG. 1 includes a perspective view of a package according to an embodiment of the invention;
[0032] FIG. 2 includes a perspective view of a receiving member of the embodiment of FIG. 1 ;
[0033] FIG. 3 includes a perspective view a the receiving member with a surgical mesh;
[0034] FIGS. 4 and 5 include perspective views of a covering member;
[0035] FIG. 6 includes an exploded view of another embodiment of the invention.
DETAILED DESCRIPTION
[0036] Reference will now be made to the drawings wherein like structures are provided with like reference designations.
[0037] Turning to FIG. 1 , a package 1 for a substantially rectangular mesh is shown in an perspective view.
[0038] Package 1 includes a receiving member 2 and a covering member 3 . In the illustrated embodiment of FIG. 1 , the package 1 is shown as rectangular; however, the package 1 may be of any suitable shape for receiving a surgical mesh.
[0039] The surgical mesh 100 can be seen in FIG. 1 or 3 .
[0040] The receiving member 2 has a generally planar shape. In the illustrated embodiment, the receiving member 2 comprises a series of resting ribs 4 protruding from an inner panel 5 .
[0041] As depicted on FIG. 2 , the receiving member 2 is thus provided with transverse ribs 4 and longitudinal ribs 4 which divide the inner panel 5 into diffusing compartments 8 as will be explained later.
[0042] In the embodiment of FIGS. 1 and 2 , the receiving member 2 is provided with four transverse resting ribs 4 and two longitudinal resting ribs 4 , which define three diffusing compartments 8 .
[0043] The resting ribs 4 include at least one groove 9 . In the embodiment of FIGS. 1 to 3 , the resting ribs 4 are provided with a series of grooves 9 spaced out at regular intervals.
[0044] In embodiments, the inner wall 5 can be provided with strengthening ribs 11 .
[0045] The receiving member 2 further includes a peripheral rim 12 .
[0046] Along each length of the receiving member 2 , the peripheral rim 12 includes a series of locking toothing 13 .
[0047] Along each width of the receiving member 2 , the peripheral rim 12 is provided with a locking pin 14 and a locking opening 15 . The peripheral rim 12 can also include one or more grooves 16 .
[0048] Turning to FIGS. 4 and 5 , a covering member 3 is shown.
[0049] The covering member 3 has a generally planar shape. The covering member 3 has a substantially planar shape and is comprised of a central portion 20 and of two lateral portions 30 extending from the central portion 20 forming substantially a H. As can be seen on FIG. 4 , the covering member 3 includes two symmetrical cut off portions 40 .
[0050] In the illustrated embodiment, the covering member 3 comprises a series of resting ribs 4 protruding from an inner panel 5 .
[0051] As depicted on FIG. 5 , the covering member 3 is thus provided with transverse ribs 4 and longitudinal ribs 4 , which define with the inner panel 5 diffusing compartments 8 .
[0052] In the embodiment of FIGS. 4 and 5 , the covering member 3 is provided with two transverse resting ribs 4 and two longitudinal resting ribs 4 , which define a diffusing compartment 8 in each lateral portion 30 .
[0053] The resting ribs 4 include at least one groove 9 . In the embodiment of FIGS. 4 and 5 , the resting ribs 4 are provided with a series of grooves 9 spaced out at regular intervals.
[0054] In embodiments, the inner wall 5 can be provided with strengthening ribs 11 .
[0055] The covering member 3 further includes a peripheral rim 12 .
[0056] Along each length of the covering member 3 , the peripheral rim 12 includes a series of locking toothing 13 .
[0057] Along each width of the receiving member 3 , the peripheral rim 12 is provided with a locking pin 14 and a locking opening 15 . The peripheral rim 12 can also include one or more grooves 16 .
[0058] The central portion 20 can include a cavity 22 provided with three retaining tabs 23 .
[0059] In an embodiment, the covering member 3 includes two weakened line 25 to form a hinge at the junction of the central portion 20 with each of the lateral portions 30 .
[0060] The surgical mesh 100 is placed onto the receiving member 2 as can be seen on FIG. 3 . The surgical mesh 100 seats on the resting ribs 4 and is surrounded by the peripheral rib 12 .
[0061] The covering member 3 is placed above the receiving member 4 and is locked onto the receiving member 2 . The locking pins 14 of the covering member 3 are engaged into the corresponding openings 15 of the receiving member 2 . The locking toothing 13 of the receiving member 2 engage into the locking toothing of the covering member 3 .
[0062] The surgical mesh 100 is thus interposed between the receiving member 2 and the covering member 3 and is maintained in a substantially flat position. The surgical mesh 100 is maintained between the resting ribs 4 of the receiving member 2 and the resting ribs 4 of the covering member 3 .
[0063] It can be noted that, within the package 1 , the gap between the resting ribs 4 of the receiving member 2 and the resting ribs 4 of the covering member 3 can be in the area of 1 mm while the surgical mesh 100 thickness can be in the area of 0.6 mm.
[0064] When positioned in the package 1 , the surgical mesh 100 is thus maintained along the resting ribs 4 ; the part of the surgical mesh 100 which is not directly interposed between the resting ribs 4 of the receiving member 2 and of the covering member is received in the diffusing compartments 8 where the surgical mesh 100 is free from contact with the package.
[0065] The surgical mesh 100 positioned in the package 1 may then be sterilized by immersion in a sterilizing solution of gas including ethylene oxide.
[0066] The sterilizing gas can flow within the package 1 and diffuses into the surgical mesh 100 through the cut off portion 40 and through the grooves 9 provided in the resting ribs 4 . The entire surface of the surgical mesh 100 is thus exposed to the sterilizing gas.
[0067] After sterilization, the package 1 can be hermetically sealed in a suitable envelope like container (not shown) to be stored for a later use.
[0068] The central cavity 22 can receive a capsule of a desiccant material to ensure that the any moisture within the surgical mesh 100 is captured. The desiccant capsule is maintained in position by the tabs 23 . The cut off portions 40 provide a significant exposure to the action of the desiccant capsule.
[0069] It can be appreciated that the receiving portion 2 and the covering member 3 are devoid of sharp angles or sharp edges thus limiting the risk of damaging the container.
[0070] When needed on an operating room, the package 1 can be presented to the medical staff.
[0071] One of the lateral portions 30 of the covering member 3 may be lifted and may be folded along the weakened line 25 thereby giving access to the surgical mesh 100 .
[0072] FIGS. 6 depicts another embodiment of the invention.
[0073] In this embodiment of the invention, the receiving member 2 and the covering member 3 are identical.
[0074] A surgical mesh 100 is positioned onto a receiving member 2 such as the receiving member 2 illustrated on FIG. 2 and a covering member 3 . The covering member 3 is structurally identical to the receiving member 2 . However, the covering member 3 further includes a cavity 22 for a desiccant capsule.
[0075] The package described herein may be made of any material suitable for sterilization such as plastic, foils, combination thereof and laminates thereof and may be formed using any suitable molding process.
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The package ( 1 ) for a surgical mesh ( 100 ) comprises:
a receiving member ( 2 ) configured and dimensioned to receive at least one surgical mesh ( 100 ), and a covering member ( 3 ) configured and dimensioned to cover the said at least one surgical mesh ( 100 ) maintaining with the receiving member ( 2 ) the surgical mesh ( 100 ) in a substantially flat position, and a gas channelling network interposed between the said receiving member ( 2 ) and the said covering member ( 3 ) configured to channel a sterilization gas within the at least one surgical mesh ( 100 ).
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BACKGROUND OF THE INVENTION
This invention is directed to a selective hydrogenation of dienes to monoolefins, particularly of cyclopentadiene to cyclopentene. More specifically, it is directed to a process whereby cyclopentadiene is selectively hydrogenated to cyclopentene through the use of a highly dispersed form of nickel in which a number of polyols that exhibit infinite or near infinite solubility in the water and insolubility in cyclopentadiene as used in this two-phase hydrogenation system. The polyols which exhibit such properties are 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2,3-propanetriol, 1,2-butanediol, 1,4-butanediol, 1,3-butanediol, 1,2,4-butanetriol and 1,2,3-butanetriol.
At the present time, substantial amounts of cyclopentadiene, usually as dicyclopentadiene, are available as a byproduct from the steam cracking of naphtha to produce primarily ethylene. Cyclopentene has been found to be useful as a monomer for the formation of general purpose elastomers by ring opening polymerization of cyclopentene. Therefore, it is desirable to convert a portion of the excess cyclopentadiene available into a more valuable raw material, such as cyclopentene.
The hydrogenation of cyclopentadiene to cyclopentene is not new. For instance, in U.S. Pat. No. 2,360,555, issued Oct. 17, 1944, there is disclosed a selective hydrogenation of one of the two conjugated double bonds of a cyclic diolefin to produce the corresponding cyclic monoolefin which is accomplished by conducting the hydrogenation in the liquid phase in the presence of an active hydrogenation catalyst, under moderate hydrogen pressure, such as 2 to 5 atmospheres absolute, and at relatively low temperatures, such as from 0° to 40° C. and even up to 100° C., using substantially less than the stoichiometric amount of hydrogen theoretically required to completely reduce the cyclic diene to the corresponding cyclic monoolefin. The catalyst therein disclosed is a pyrophoric nickel metal catalyst, such as Raney nickel. It is also disclosed that it is desired to conduct the reaction in dilute solution. The dilution may be affected by the addition of any solvent, stable under conditions of the process and which is not a catalyst poison and whose boiling point is such as to render it easily separable from the reaction mixture. Benzene and ethanol as well as tetralin, dioxane, isooctane, ethyl ether and diisopropyl ether are disclosed as such solvents in such process.
In U.S. Pat. No. 3,819,734, issued July 25, 1974, there is disclosed the hydrogenation of cyclopentadiene to cyclopentene by bringing cyclopentadiene into contact with a catalyst consisting essentially of (1) nickel, on a magnesium or zinc oxalate support, (2) a ligand selected from the group consisting of trimethyl phosphine, triethyl phosphine, methyl ethyl propyl phosphine, trimethyl phosphite, triethyl phosphite, tributyl phosphite, triphenyl phosphite, etc., while in the presence of hydrogen, at temperatures from 0° C. and at pressures from 0 to 1000 pounds per square inch gauge. The solvent mentioned therein is ethanol.
In U.S. Pat. No. 3,994,986, issued Nov. 30, 1976, there is disclosed the preparation of cyclopentene from cyclopentadiene by hydrogenating cyclopentene with hydrogen gas at a ratio of 1 to 1.5 moles of hydrogen per mole of cyclopentadiene in the presence of a palladium catalyst on a carrier.
Also, in U.S. Pat. No. 3,857,894, issued Dec. 31, 1974, there is disclosed the hydrogenation of cyclopentadiene to cyclopentene in the presence of a palladium catalyst and a small amount of an aqueous solution of zinc salt having a water/zinc ratio of at least 1/1 by weight.
The cyclopentadiene employed in the formation of cyclopentene by hydrogenation is usually obtained by depolymerizing or cracking dicyclopentadiene. In order to obtain cyclopentadiene for the hydrogenation of this invention, the depolymerization of dicyclopentadiene is accomplished by heating the dimer at a temperature above 150° C. under atmospheric pressure in a conventional cracking apparatus. The depolymerized material should be hydrogenated without substantial delay because it is also known that redimerization will occur upon standing.
SUMMARY OF THE INVENTION
According to the invention, cyclopentadiene can be selectively hydrogenated to cyclopentene in the liquid phase by contacting cyclopentadiene with hydrogen in the presence of a catalyst comprising a highly dispersed form of nickel and in which a polyol selected from the group of 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2,3-propanetriol, 1,2-butanediol, 1,4-butanediol and 1,2,3-butanetriol, is employed in the reaction mixture.
It has been found that in order to have a fairly selective hydrogenation of cyclopentadiene to cyclopentene, a reaction medium or diluent must be employed. Thus, according to the present invention, a polyol that exhibits near infinite or infinite solubility in water and insolubility in cyclopentadiene can be employed in the reaction mixture to form a two-phase hydrogenation system.
The use of these polyols as a reaction medium or in the reaction mixture has the further advantage since the cyclopentadiene and the cyclopentene are not soluble in these polyols, the process of this invention is a two-phase liquid system. This two-phase system thereby provides a method for the separation of the reaction medium or polar phase from the organic phase which contains cyclopentene and the unreacted cyclopentadiene. Another advantage is that the use of polyol reaction medium allows the cyclopentadiene feedstock which has been formed by steam cracking of dicyclopentadiene to be employed without further drying.
DETAILED DESCRIPTION OF THE INVENTION
The temperature at which cyclopentadiene may be hydrogenated in accordance with this invention may range from 0° to 75° C. with 20° to 30° C. being most preferred. Temperatures that approach 100° C. tend to consume the cyclopentadiene in side reactions, such as dimerizations back to dicyclopentadiene and other undesirable side reactions. Generally speaking, both temperature and the pressure of hydrogen employed should be kept as low as possible consistent with reasonable rates of hydrogenation. When faster rates of reaction than that being obtained are desired, it is preferable to increase the rate of hydrogenation by means of increased hydrogen pressure rather than an increase in the temperature.
Extremely high pressures may be employed in the hydrogenation of this invention to effect faster rates of hydrogenation. However, it has been found that hydrogen pressure, such as 400-450 psig -- 2756-3100.5 kPa is all the pressure that is required to give reasonable rates of reaction.
Because the polyols of this invention are not conducive to the solubility of the cyclopentadiene and thereby cause the process to be a two-phase system, vigorous agitation is required during the hydrogenation. When this vigorous agitation is being obtained, the polyols serve as a heat sink by absorbing unwanted heat from the reaction site and, hence, moderate the hydrogenation, thereby enhancing the selectivity to cyclopentene.
The presence of a two-phase system when the agitation is stopped also offers the advantage that the catalyst settles to the bottom of the lower polyol layer and no residual hydrogenation of the organic layer occurs if a lengthy time is required to remove the reaction product, cyclopentene. The polyol also serves to protect the catalyst from air and thereby facilitates an easy recycling of the catalyst.
The catalyst employed in the present invention is a highly dispersed form of nickel. However, a Raney nickel-type catalyst is preferred. Methods for preparing the Raney nickel catalyst which are useful in this invention are known and can be found in a book entitled "CATALYTIC HYDROGENATION", by Robert L. Augstine, published in 1965 by Marcel Dekker, Inc., New York, N.Y.
Temperatures employed to prepare Raney nickel do not vary widely and are disclosed in this reference. The author refers to these Raney nickel catalysts as W1, W2, W3, W4, W5, W6, W7, and W8. In addition to the W-type Raney nickel, a Raney nickel referred to as T-1 is preferred, or a modification of T-1 Raney nickel is preferred.
In the Journal of Organic Chemistry 26, 1625 (1961), there is described a process for the preparation of what the authors refer to as T-1 Raney nickel by Dominguez, Lopez and Franco. In this article, the authors state that the preparation of the T-1 Raney nickel catalyst is a modification of the procedure described by Papa, Schwenk and Whitman in the Journal of Organic Chemistry 7, 586, (1942) and Papa, Schwenk and Brieger in the Journal of Organic Chemistry, 14, 366, (1949). All of the Raney nickels described in the articles referred to above are operable in the process of this invention.
Other nickel catalysts useful in the invention can be obtained by the use of new techniques known to the catalyst art for depositing metals on suitable supports in a highly dispersed form. These nickel catalysts would exhibit catalytic properties similar to the properties exhibited by the Raney nickel catalysts.
In the article by Dominguez et al, the authors state that the T-1 Raney nickel is prepared as follows:
To a 1-liter 3-neck flask containing 600 milliliters (ml) of a 10 percent sodium hydroxide solution, 40 grams of Raney nickel aluminum alloy (50 percent nickel) were added in small portions over a period of 20 to 30 minutes with mechanical stirring. The temperature was kept at 90°-95° C. during this addition. The mixture was stirred for an additional hour period at which time the stirring was stopped and the nickel was allowed to settle, and the solution decanted. The metal was washed five times with 200-ml portions of water and then five times with 50-ml portions of ethanol in such a manner that the nickel was always covered with liquid. The catalyst was then stored under ethanol and refrigerated for further use.
The Raney nickel employed in some of the examples of this invention and termed by the present inventor as Modified T-1 Raney nickel was prepared by a slight modification of Dominguez et al's procedure as follows:
A solution of 2 grams of sodium hydroxide in 50 ml of water was heated to its boiling point and then there was added 2 grams of Raney nickel aluminum alloy (1 gram of Raney nickel) as rapidly as the hydrogen evolution would permit. This mixture was then digested at 95° to 100° C. for 1/4 hour (reflux) and the water was continually replaced as it evaporated. The solution was decanted from the Raney nickel and the metal washed with three 250-ml portions of cold water. This catalyst was employed without washing with ethanol.
The ratio of catalyst to cyclopentadiene is not too critical. It has been found satisfactory results are obtained when about one part by weight of catalyst per 500 parts by weight of cyclopentadiene are employed. When a catalyst to cyclopentadiene weight ratio greater than about 1 to 33 is employed, the catalyst is being wasted.
The amount of polyol employed should range from about a volume ratio of polyol to cyclopentadiene of about 1/1 to about 4/1.
The present invention can be applied to continuous or batch process. While the ratio of catalyst to cyclopentadiene set forth is more applicable to batch processing, those skilled in the art could readily adapt the reactants to the catalyst and reaction conditions to continuous processing.
The practice of this invention is further illustrated by reference to the following examples which are intended to be representative rather than restrictive of the scope of the invention. Unless otherwise indicated, all parts and percentages are by weight.
EXAMPLE 1
A 1-liter stainless steel reactor was swept with nitrogen and charged with 200-ml of ethylene glycol containing 1.0 gram of modified T-1 Raney nickel suspended by swirling. Sixty-six grams (1.0 mole) of cyclopentadiene containing 5 ml of pentane as an internal standard was then added under nitrogen. The sealed reactor was then charged with 450 psig -- 3100.5 kPa of hydrogen with stirring. The reactor was held at 25° C. with internal cooling coils and the reaction was stopped when 85-95% of the theoretical amount of hydrogen had been consumed (57 min). The reaction was stopped by stopping the stirring and venting the hydrogen pressure to one atmosphere. The top cyclopentene layer was withdrawn for gas chromatographic analysis. The analysis revealed a 90.7 percent conversion of cyclopentadiene and a 96.7 percent selectivity to cyclopentene, with a 3.3 percent selectivity to cyclopentane.
EXAMPLE 2
A reaction was carried out under the conditions of Example 1 except that 100-ml of ethylene glycol was employed and the reaction was carried out for 75 minutes. Gas chromatographic analysis revealed:
89.5% conversion cyclopentadiene
90.5% selectivity cyclopentene
8.3% selectivity cyclopentane
EXAMPLE 3
A reaction was carried out under the conditions of Example 1, except that 300-ml of ethylene glycol was employed and the reaction was carried out for 75 minutes. Gas chromatographic analysis revealed:
85.6% conversion cyclopentadiene
92.4% selectivity cyclopentene
1.4% selectivity cyclopentane
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.
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There is disclosed a process for the preparation of cyclopentene which comprises selectively hydrogenating cyclopentadiene in the liquid phase by contacting cyclopentadiene with hydrogen in the presence of a hydrogenation catalyst comprising a highly dispersed form of nickel in which a polyol selected from the group consisting of 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2,3-propanetriol, 1,2-butanediol, 1,4-butanediol, 1,3-butanediol, 1,2,4-butanetriol and 1,2,3-butanetriol is employed in the reaction mixture.
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BACKGROUND
This section is intended to introduce the reader to various aspects of art, which are related to various aspects of the present invention that are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present invention. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
Graphical visualizations, such as bar charts or line charts are commonly used to display data streams. Financial data such as stock market information and status information about a computer network are two examples of data that a user may desire to view graphically. For large amounts of data, first layer visualizations are typically not detailed enough to effectively display the data stream. For this reason, second layer, third layer, or even lower layer (i.e. more detailed) visualizations can also be created to provide increased resolution of the data within the data stream. For complex or large data streams, the creation of meaningful visualizations is often difficult and burdensome.
The visualizations mentioned above are created many ways. First, the lower layer visualizations can be created by pre-programming a software program to display a pre-defined sequence of visualizations. For example, in a financial context, the user programs the software to display a first layer visualization of stock market performance and then to display lower layer visualizations of certain pre-selected stocks. While this technique permits display of detailed information from the data stream, it disadvantageously limits the display to only the pre-selected data (i.e., the specific stocks pre-selected by the user). A second type of sequence of visualizations permits a user to manually drill down to a lower layer visualizations by selecting a portion of the first layer (or lower layer) visualization to expand. While this technique permits the creation of lower layer visualizations that display the specific information desired by a user, this technique often involves manual interaction with the first layer visualization and thus is not often suitable for automated reporting.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of one or more disclosed embodiments will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a block diagram of a computer system illustrating one embodiment of the present invention;
FIG. 2 is a process flow illustrating one embodiment of a process for creating a sequence of visualizations;
FIG. 3 illustrates one embodiment of a data stream displayed as a spreadsheet;
FIG. 4 illustrates one embodiment of a graphical user interface displaying an exemplary first layer visualization;
FIG. 5 illustrates one embodiment of a graphical user interface displaying an exemplary second layer visualization;
FIG. 6 illustrates one embodiment of a graphical user interface displaying an exemplary third layer visualization;
FIG. 7 illustrates one embodiment of a graphical user interface displaying an exemplary third layer visualization;
FIG. 8 illustrates one embodiment of a graphical user interface displaying an exemplary first layer visualization; and
FIG. 9 illustrates one embodiment of a graphical user interface displaying an exemplary first layer visualization.
DETAILED DESCRIPTION
One or more specific embodiments of the present technique will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine understanding of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
The present application is directed towards a system that can create visualizations based on interaction rules instead of pre-selected data. These interaction rules interact with the data in the data stream to create a sequence of visualizations that are customized to the particular data in the data stream. This feature is particular advantageous in the context of automated, periodic reporting because the system interacts with the data with each periodic reporting to create visualizations that display the information that is most important to a particular user.
FIG. 1 is a block diagram illustrating one embodiment of a computer system 10 . The computer system 10 includes a processor 11 , an intelligent interface 12 , a visualization constructor 14 , and an image compositor 16 . In one embodiment, the processor 11 comprises the intelligent interface 12 , the visualization constructor 14 , and the image compositor 16 . In another embodiment, the processor 11 interacts with the intelligent interface 12 , the visualization constructor 14 , and the image compositor 16 . The processor 11 comprises any one of a number of suitable processors. In one embodiment, the processor 11 is located within a computer system.
As will be described in greater detail below, the intelligent interface 12 interacts with the visualization constructor 14 to generate a sequence of data-driven multi-layered visualizations. The intelligent interface 12 is configured to import incoming data at a specified time interval. The intelligent interface 12 also interfaces with the visualization constructor 14 to set a color scale for the visualization and to lay out for the visualizations. In one embodiment, application interfaces (“APIs”) within the intelligent interface 12 perform this task. Further, the intelligent interface 12 generates a set of interaction rules to guide the visualization constructor 14 in creating the sequence of data-driven visualizations
The visualization constructor 14 constructs a sequence of multi-layered data-driven graphs and images for real-time data exploration without user interaction. This visualization technique is driven by the data instead of the user. In particular, the visualization constructor 14 generates the sequence of graphical visualizations by simulating window-like properties, such as window height, window width, window framing, and window panels. In one embodiment, the visualization constructor 14 creates the sequence of graphical visualizations with a default window configuration that is based on the origin and dimensions of the computer screen. For example, the visualization constructor 14 can create the sequence of visualization as a rectangle with an origin and dimensions of 10, 50, 1000, and 6000. In alternate embodiments, however, other window configuration based on the incoming data can be used. The visualization constructor 14 can also use drilldowns, filtering, or zooming to generate different types and levels of visualization to most efficiently display the data stream.
The image compositor 16 transforms the visualizations generated by the visualization constructor 14 into an image file, such as JPG file. In one embodiment, the image compositor 16 also exports the image files to a storage medium. In another embodiment, the image compositor 16 composes the image files into a computer slideshow. In yet another embodiment, the image compositor 16 creates an image file that permits a user to get more detailed information by pointing a graphical pointer at part of the image. In still another embodiment, the image compositor 16 composes the image files on a web page.
Those skilled in the art will appreciate that the intelligent interface 12 , the visualization constructor 14 , and the image compositor 16 can be hardware, firmware, software, or some combination of hardware, firmware, and software. In alternate embodiments, the intelligent interface 12 , the visualization constructor 14 , and the image compositor 16 do not necessarily solely comprise the functions as illustrated. In other words, the functions attributed to the intelligent interface 12 , the visualization constructor 14 , and the image compositor 16 are merely one example and other embodiments can be envisaged wherein the functions described above are split up differently or wherein some components are not included or other components are included.
FIG. 2 is a process flow illustrating one embodiment of an exemplary process 50 for creating a sequence of data-driven visualizations. The process 50 begins by importing a data stream, as indicated in block 52 . In one embodiment, importing the data stream comprises receiving a transmission from a data collection source. In another embodiment, importing the data stream comprises communicating with a storage medium to download the data. In some embodiments, data is imported periodically. For example, the computer system 10 can download the data stream once every fifteen minutes.
Once the data in the data stream has been imported, the process 50 continues with data selection, as indicated in block 54 of FIG. 2 . Data selection is employed because the data stream can comprise more data than the user wishes to display in the sequence of graphical visualizations. For this reason, during this step of the process 50 , the intelligent interface 12 can select a subset of information from the data stream to be displayed. For example, in one embodiment, data selection comprises selecting all of the data in the data stream. In alternate embodiments, data selection comprises selecting only a subset of the data in the data stream. In one embodiment, this selection is performed by a set of application interfaces (“APIs”) that interface with the visualization constructor 14 to limit what data is displayed in the sequence of graphical visualizations. In addition, during the data selection process, the intelligent interface 12 uses the set of APIs to set a color scale and lay out a structure for the sequence of graphical visualizations. The color scale and structure for the sequence of visualizations are either be programmed in advance by the user or generated by the intelligent interface 12 based on the selected data.
Once data selection is complete, the intelligent interface 12 generates a set of interaction rules, as indicated in block 56 . The interaction rules specify which visualizations will comprise the sequence of visualizations and in what order the sequence of visualizations will be displayed. The interaction rules are based both on the structure of the selected data and the selected data itself. In one embodiment, the interaction rules are generated by accessing a list of stored user preferences, determining how the data corresponds to the stored user preferences, and generating the interaction rules based on the correspondence between the data and the stored user preferences. For example, in a stock market reporting context, the user preferences could specify creating a sequence of visualizations comprising a graphical visualization of overall performance of the stock market and creating lower layer graphical visualizations for the three stocks that increased in value the most during the previous 24 hours. The intelligent interface 12 employs these user preferences to generate the interaction rules, which provide a framework that permits the visualization constructor 14 to create visualizations that are based on the data itself. This sequence of visualizations displays detailed information that is of interest to the user (i.e., information about the three stocks with the greatest increase in value) without the user having to manually select the particular stocks to be displayed.
Once generated, the interaction rules provide detailed information about what data is to be displayed in the sequence of visualizations, and thus, the interaction rules serve as a guide to the visualization constructor 14 in constructing the sequence of visualizations. In one embodiment, the interaction rules can be generated based on instructions pre-programmed into the intelligent interface 12 . In alternate embodiments, the interaction rules are generated by the intelligent interface 12 , itself based on the data selected.
After the interaction rules have been generated, the visualization constructor 14 simulates a window in which to construct the sequence of visualizations. In one embodiment, the visualization constructor 14 simulates a window that resembles windows created in the Microsoft Windows™ operating system. In one embodiment, this window has a height and a width that corresponds to the edges of a display and includes frames and panels that create boundaries for the window. In one embodiment, all of the visualizations in the sequence of visualizations employ windows that have similar properties. In alternate embodiments, however, the properties of the individual window will vary depending on the properties of the data being displayed in the particular graphical visualization.
Once the first layer visualization has been created, the visualization constructor 14 can create the lower level visualizations, as indicated by block 62 . As stated above, the visualization constructor 14 employs the set of interaction rules generated by the intelligent interface 12 to guide the construction of the lower level visualizations. Specifically, the visualization constructor 14 creates lower level visualizations to display any data or class of data specified in the interaction rules.
Next, returning to the process 50 in FIG. 2 , the visualization constructor 14 creates the first layer visualization, as illustrated in block 60 . The first layer visualization is created in the window simulated by the visualization constructor 14 . The first layer visualization comprises virtually any type of visualization, including, but not limited to, an icon, a graphic, a bar graph, a pie chart, a pistol chart, or a line chart. In one embodiment, the first layer visualization employs color to more effectively present data.
FIG. 3 illustrates one embodiment of an exemplary data stream 70 displayed as a spreadsheet. The data stream 70 comprises a collection of information relating to requests for Internet service. For example, as shown in the columns 72 , 74 , 76 , the data stream 70 comprises information relating to one or more customers, one or more services provided to the customers, and one or more websites supported. Further, as seen in columns 78 , 80 , 82 , and 84 , the data stream 70 also comprises information on the number of service level object (“SLO”) violations (i.e., when service was not provided within a pre-determined time threshold) for each website that was provided service (column 78 ). In this column, a “one” represents a SLO violation and a “zero” represents the absence of an SLO violation. The column 80 represents availability, column 82 setup time, and column 84 response time. Lastly, column 86 represents a date/time stamp for the particular service request. Even though the data stream 70 is illustrated in FIG. 3 as a spreadsheet, those skilled in the art will appreciate that in alternate embodiments, the data stream can be stored or represented in a variety of forms, including, but not limited to, a database and a linked list. Further, it will be appreciated that the data stream is shown in an abbreviated form for illustrative purposes. In alternate embodiments, the data stream comprises a thousand or more data entries.
In regards to the exemplary data stream 70 illustrated in FIG. 3 , the interaction rules specify which providers or which websites will be displayed in the sequence of graphical graphs. For example, the interaction rules specify creating a first layer visualization that displays the volume of service for each of the providers 1 and 2 along with the number of SLO violation ( FIG. 4 ). Further, the interaction rules specify creating lower layer visualizations to display response time for the provider with most SLO violations ( FIG. 5 ) and the set-up time and availability of the individual website from that provider with the worst response time ( FIGS. 6 and 7 ).
FIG. 4 illustrates one embodiment of a graphical user interface displaying an exemplary first layer visualization 100 . The first layer visualization 100 is based on the data stream 70 described in regard to FIG. 3 . Further, the first layer visualization is created by employing the exemplary interaction rules discussed above. Specifically, the first layer visualization 100 displays a visualization of the total volume of service for each of the providers from the data stream 70 along with a visualization of the number of SLO violations.
In particular, the volume of service is arrayed along a y-axis 102 , and the two service providers are displayed as graphical bars 104 and 106 . Each of the graphical bars 104 and 106 is subdivided into two regions to represent the number of service requests to each provider that resulted in SLO violations versus the number of requests that did not result in an SLO violation. For example, the graphical bar 104 is divided into a region 108 which displays the number of requests that resulted in an SLO violation and a region 110 which represents the number of requests that were provided service. Similarly, graphical bar 106 is divided into regions 112 and 114 . Those skilled in the art will appreciate that dividing the graphical bars 104 and 106 into visually distinctive regions merely adds an additional dimension to the first layer visualization 100 . In alternate embodiments, the graphical bars 104 and 106 are subdivided differently or are not subdivided.
The first layer visualization 100 also comprises a legend 116 which indicates to a viewer of the first layer visualization 100 what the sub-regions of the graphical bars 104 and 106 represent. In some embodiments, the legend 116 is omitted from the first layer visualization 100 . In one embodiment, the first layer visualization 100 is also configured to support pointer-driven value display. In one embodiment, when a pointer is pointed at the sub-section of the visualization, the value of a sub-section of the visualization is displayed. For example, FIG. 4 illustrates an exemplary pointer and value 118 .
Those skilled in the art will also appreciate that the graphical bars 104 and 106 shown in the first layer visualization 100 are merely one technique for displaying the data stream. In alternate embodiments, other types of visualizations, such as pistol charts, line charts or pie charts, can be employed to represent the data stream. In still other embodiments, the first layer visualization is arranged hierarchically with different levels of the hierarchy displayed through differing shades or colors.
FIG. 5 illustrates one embodiment of a graphical user interface displaying an exemplary second layer visualization 150 . The second layer visualization 150 is based on the data stream 70 described in regard to FIG. 3 . Further, the second layer visualization 150 is created by employing the exemplary interaction rules discussed above. Specifically, the second layer visualization 150 displays the response times by website for the provider with most SLO violations. As stated above, in alternate embodiments, the interaction rules could have specified that the second layer visualization 150 be created to display any one of a number of elements of the data stream.
In one embodiment, the second layer visualization 150 expands on one of the graphical bars displayed in the first layer visualization 100 . This expansion is also referred to also drilling down or creating a drilldown visualization. In the case of the second layer visualization 150 , it is a drilldown graphical visualization from the graphical bar 104 . As with the first layer visualization 100 , the second layer visualization 150 comprises a y-axis 152 , which represent the number of service requests. In the second layer visualization 150 , the three websites with highest volume of service requests for provider 1 are arrayed along the x-axis. Those skilled in the art will appreciate that three websites are shown illustrative purposes only, and in alternate embodiments, the interaction rules could have specified that any one number of a number of sub-elements from the graphical bar 104 comprise the second layer visualization 150 .
The second layer visualization 150 comprises graphical bars 154 , 156 , and 158 which represent service requests to each of the three websites. As with the graphical bars 104 and 106 shown in FIG. 4 (from column 70 of FIG. 3 ), the graphical bars 154 , 156 , and 158 are sub-divided into a series of visually distinctive regions from the graphical bar 104 . In the case of the second layer visualization 150 , each of the graphical bars 154 , 156 , and 158 is divided into a series of regions corresponding to the response time of each individual service request with the total response time displayed above each of the graphical bars 154 , 156 , and 158 . In this embodiment, the second layer visualization 150 also comprises a legend 160 to display which usual distinctions correspond to which response times in the second layer visualization 150 . Those skilled in the art will also appreciate that the graphical bars 154 , 156 , and 158 shown in the second layer visualization 150 are merely one technique for displaying the data stream. In alternate embodiments, other types of visualizations, such as graphics, icons, line charts, pistol charts, or pie charts, can be employed to represent the data stream. In one embodiment, the second layer visualization 150 is configured to support pointer-driven value display. In one embodiment, when a pointer is pointed at the sub-section of the visualization, the value of a sub-section of the visualization is displayed. For example, FIG. 5 illustrates an exemplary pointer and value 162 .
The visualization constructor 14 ( FIG. 1 ) can also create additional lower level visualizations to display any data or class of data specified in the interaction rules. For example, FIG. 6 illustrates one embodiment of a graphical user interface displaying an exemplary third layer visualization 250 . The third layer visualization 250 displays the set-up time of the individual website from the second layer visualization 154 with the worst response time (i.e., graphical bar 154 ). The third layer visualization 250 illustrates four regions 252 , 254 , 256 , and 258 representing the volume of requests corresponding to particular ranges of setup times. For example, the region 252 indicates the number of requests that had a setup time between 2.5 seconds and 4 seconds, whereas the region 258 indicates the number of requests with setup times between 1.1 seconds and 1.2 seconds. As illustrated, the third layer visualization 250 also comprises a legend 260 to indicate to a viewer what the visual indicators (e.g. colors) of each region represent. In alternate embodiments, the legend is omitted.
In further example, FIG. 7 illustrates one embodiment of a graphical user interface displaying an exemplary third layer visualization 300 . The third layer visualization 300 displays information regarding the availability of the website from the second layer visualization 150 with the highest response time (i.e., the graphical bar 154 ). For example, the third layer visualization 300 comprises regions 302 and 304 that indicate availability for the website www.attws.com. As illustrated, the region 302 indicates availability (represented in a legend 306 as a one) and the region 304 indicates non-availability (represented in the legend 306 as a zero).
The visualization constructor 14 is also capable of creating more detailed first layer visualizations than the first layer visualization 100 , if so specified in the interaction rules. For example, FIG. 8 illustrates one embodiment of a graphical user interface displaying an exemplary first layer visualization 350 . Unlike the first layer visualization 100 which provided only summary data for the providers 1 and 2 , the first layer visualization 350 displays more detailed information relating to the number of SLO violations for each of the services provided by each of the providers and organizes this information by date and time stamp (i.e., the numbers running across the top of first layer visualization 350 ). Similarly, FIG. 9 illustrates another embodiment of a graphical user interface displaying an exemplary first layer visualization 400 . The first layer visualization 400 displays even more detailed information than the first layer visualization 350 by display both SLO violations and response time for each of the each of the websites of each of the providers. As illustrated in both first layer visualization 350 and first layer visualization 400 , shading can be used to highlight the different providers or to bring a third dimension to the visualization.
After the visualization constructor 14 has created the sequence of visualizations, the visualization constructor 14 ranks the sequence of visualizations and places the visualizations into an order, e.g. ascending, descending, and the like, based on the relative position of the data represented in each of the visualizations in the data stream 70 . In one embodiment, this ranking is used to order the sequence of visualizations for automated display in computer slide show.
Returning to FIG. 2 , once the visualization constructor 14 has ranked and ordered the sequence of visualizations, the image compositor 16 transforms the sequence of visualizations into a sequence of images, as indicated by block 64 . In alternate embodiments, the images are created by the visualization constructor 14 . In one embodiment, the image compositor 16 also selects a foreground and background color for the image. In another embodiment, the image compositor 16 can also enlarge or shrink the size of each image. In yet another embodiment, the image compositor 16 can save the images as a sequence of image files, such as JPG files, or compiles the images into a presentation, such as a computer displayed slideshow. In still another one embodiment, this slideshow can be automated and thus configured to display each of the images for a predetermined amount of time. In another embodiment, the image compositor 16 creates an image in which a user is able to get more detailed information from the image by pointing a graphical pointer at a part of the image. In still another embodiment, the image compositor 16 stores the images on a storage medium, such as a shared disk drive. In a final embodiment, the image compositor 16 composes the images for display on either an internal web page or a World Wide Web page.
While the invention can be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.
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There is provided a method and an apparatus for creating visualizations. Specifically, there is provided a computer-implemented method for creating visualizations, the method comprising importing data, generating an interaction rule for the data, and creating a visualization using the data and the interaction rule. An apparatus for implementing the method is also provided.
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BACKGROUND OF THE INVENTION
The phosphate rock industry is an outstanding example of industrial and ecological achievement through the use of modern mining techniques, improved ore dressing methods and novel ecologically oriented practices.
New developments in each of these areas has resulted in increased output and recovery of the vital mineral product from the mineral deposit, marked extension of the life of the phosphate fields and conservation of water resources through recycle. The improved practices have also resulted in elimination or minimization of land and water pollution hazards normally associated with disposal of waste slimes produced in ore processing plants and in the reclamation of otherwise useless land by formulating waste slimes and tails into a reconstituted fertile soil having acceptable bearing strength. Processes for achieving these desirable results are described in U.S. Pat. to C. C. Cook and E. M. Haynsworth, No. 3,718,003; No. 3,763,041 and No. 3,761,239, issued Feb. 27, Oct. 2 and Sep. 25, 1973, respectively, and M. L. Lassiter, No. 3,940,071, issued Feb. 24, 1976.
The benefits derived from these improved practices are dramatic and accrue to both the industry and the public alike. However, these benefits are not derived without (a) utilization of additional equipment, (b) an increase in the labor force required to install, operate and maintain said equipment, and (c) a marked increase in power consumption.
Now, in light of diminishing fuel reserves, skyrocketing costs for electrical energy and significantly increasing equipment costs, especially for large diameter steel pipe required by the modern practices for moving high pressure water, tailing, slimes and matrix between the mine, the phosphate recovery plant and the waste disposal area, it becomes exceedingly apparent that still further technological advances are required to achieve the desirable results afforded by the above-mentioned practices; but, to achieve such results with greatly reduced power consumption and minimized equipment and labor costs.
The magnitude of the problems confronting the industry, as regards increasing energy costs and usage of large diameter steel pipe is evidenced by the fact that energy costs for a typical modern phosphate mining operation have nearly quadrupled in the past five years; and further, by the fact that such an operation will normally require replacement of approximately 20,000 to 30,000 feet of large diameter, i.e. 16 to 20 inches, steel pipe annually.
It is, therefore, an object of the present invention to provide an improved method and apparatus for processing hydraulically mined ore slurries, particularly phosphatic ore slurries, whereby power consumption per ton of ore processed is markedly reduced.
It is also an object of this invention to eliminate or minimize pipe errosion and maintenance problems encountered in the conventional processing of hydraulically mined ore slurries by replacing the slurry pump transport of matrix and plant tailings with an endless belt conveyor system.
It is a further object of this invention to provide a method for processing matrix slurries, wherein said matrix slurries are dewatered and deslimed at or near the active mining operation such that pumping of the matrix slurry over extended distances is eliminated.
It is a still further object of this invention to provide a method for transporting wet, deslimed, phosphate matrix from an active mining operation to an ore dressing plant via a continuous belt, while simultaneously transporting tailings from the ore dressing plant for use at a land reclamation excavation, near or adjacent the active mining operation, using the same said continuous belt.
SUMMARY OF THE INVENTION
This invention relates to a method of processing hydraulically mined ore slurries, containing in addition to the mineral values, substantial quantities of contaminating argillaceous material (clay) and silica.
Among the ores which can be processed in accordance with the method of the present invention are non-metallic ores such as phosphate, potash, feldspar, clays and fluorspar, and metallic ores such as titanium and rutile. For the purpose of clarity, it is most convenient to describe this invention in terms of a particular ore processing industry, such as the phosphate industry, although the present process is not necessarily limited to the processing of phosphate ore.
In the surface mining of phosphate ores over-burden covering the phosphate rock is removed by any convenient means, as for example with a dragline, bulldozer, steamshovel, or the like. The phosphate bearing ore comprising, argillaceous material (clay), quartz or silica, mineral values and extraneous gangue, is then dug from the deposit, generally with a dragline, and deposited as a mound of loosely consolidated ore matrix in front of a pit gun car. Hydraulic pit guns, mounted on the car, are used to direct streams of high pressure water at the matrix forming it into a slurry.
According to the invention, this matrix slurry is pumped to slurry treatment apparatus at an intermediate station where it is sized, deslimed, dewatered and deposited on an endless belt for transport to the phosphate ore dressing plant for further refining.
In contrast to the typical phosphate mining operation, desliming at a station near the pits can reduce the volume of materials handling by as much as 100 to 300 tons per hour.
The term, intermediate station, as used herein, is intended to mean those parts of the treating and transport apparatus located in the vicinity of the active mining pits for concentrating solids from the matrix slurry for transport by conveyor belt to a more remote processing plant, and for reslurrying the return tailings. This arrangement is a total departure from conventional practices. Similarly, the location of waste disposal areas near or adjacent the active mining operation is another recent departure from conventional phosphate mining practices. This latter arrangement is particularly advantageous in conjunction with the present invention, since it provides for waste disposal of slimes with minimized transport and requires little, if any, additional electric power.
In a preferred operation, the intermediate station is situated where the slimes can be delivered from the intermediate station to the disposal area by gravitational flow. Depending on the terrain in which the mining is carried out, in some cases some pumping facilities may be required for moving slimes to the waste disposal area.
Yet another departure from conventional phosphate mining practices is the use of an endless belt to convey dewatered and deslimed matrix over a long distance from the intermediate station to the phosphate recovery plant. This arrangement reduces power consumption and eliminates many problems formerly associated with the maintenance and replacement of the slurry pumps and the long distance, large diameter pipelines used to deliver matrix slurry from the mines directly to the ore dressing plant. In addition, in a preferred practice of the present invention, dewatered sand tailings from the ore dressing plant are deposited on the returning strand of the continuous belt and carried to the intermediate station near the disposal area where the tailings are slurried and transported by a slurry pipeline over the short distance to the disposal area. The sand tailings slurry is sprayed over thickened slimes in the disposal area.
The invention in some preferred embodiments thus combines an improved method for transporting and processing the ore matrix with improvements in a continuous land reclamation method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagrammatic sketch of a preferred process of this invention.
FIG. 2 is a diagrammatic sketch of a preferred process of this invention especially designed for the treatment of phosphate ores which contain substantial quantities of compacted clays (mudballs) in which phosphate values are entrapped.
FIG. 3 is a cross-sectional view of the idler support system for the continuous belt.
FIG. 4 is a side view of the continuous belt drive module; and
FIG. 5 is a cross-section of the continuous belt drive module.
FIG. 6 is a graphic presentation of data tabulated in Table 1.
Now referring to FIG. 1, a stream of high pressure water is directed at a loosely consolidated mound of phosphate matrix. The stream washes the matrix into a sump 1 from which the slurried matrix, containing approximately 35% solids, is withdrawn by means of pit pumps 2.
The slurry is pumped over a short distance under high pressure through a large diameter pipe 3 to an intermediate station which is relatively nearer to the mine than the ore processing plant. The slurry is delivered first to a grizzly 4 where plus 3-inch materials such as rocks, mudballs and extraneous gangue, are removed. The plus 3-inch waste from the grizzly is deposited on a waste conveyor 5 and sent to a waste disposal area where it becomes a constituent in the continuous land reclamation process.
Alternatively, where the plus 3-inch material from the grizzly 4 is primarily compacted clay (mudballs) containing entrapped phosphate values, said mudballs can be slurried in water to about 60% to 80% solids by weight and subjected to jets or streams of high pressure water, preferably in the 125 to 175 psig. range. The mudballs are disintegrated by the high velocity jets, not shown, and the slurry is recycled to the grizzly for further treatment.
Another alternative to the disposal of plus 3-inch mudballs is the use of ultrasonic waves to disintegrate the mudballs (not shown). In this alternative method of treatment, the mudballs from grizzly 4 are slurried to about 20% to 40% solids by weight and the slurry is subjected to sonic waves in a frequency range of about 75 to 100 cycles per second. The thus-treated slurry is then recycled to the grizzly 4 for further treatment.
Minus 3-inch material passing the grizzly 4 is deposited on a 3/4-inch screen 6 to separate minus 3-inch plus 3/4-inch matrix from the minus 3/4-inch matrix slurry which is used as cyclone feed.
The minus 3-inch plus 3/4-inch matrix from screen 6 is then crushed to pass through the 3/4-inch screens. While the crusher 7 is shown as an impactor, other types of crushers, such as hammer or rodmills, can be used to reduce this minus 3-inch plus 3/4-inch matrix fraction to the desired minus 3/4-inch particle size.
Crushed product from the impactor 7 is deposited in a slurry holding tank 8, equipped with an agitator, not shown, for dispersing and maintaining the crushed product in a slurry. This slurry is recycled by pump means 9 to the 3-inch grizzly 4.
The minus 3/4-inch slurry which passes the screen 6 is sent to a matrix slurry holding tank 10, where the solids concentration of the matrix slurry is adjusted to about 20% to 30% solid, and preferably to about 25% solids. In practice, we have found that slurries having a solids concentration below about 20% generally result in excessive deposition of water on the belt due to inadequate cyclone separation. Likewise, slurries having more than about 30% solids concentration do not lend themselves to cyclone desliming, but rather, yield a matrix contaminated with excessive slimes.
The term, "slimes," as used herein, refers to aqueous suspensions or dispersions of ultrafine solid wastes most of which are ordinarily separated from the ore feed stream prior to the flotation step. More particularly, slimes are the ultrafine soil solids associated with the ore such as; for example, clays, quartz, and mineral values, the solid particles of which are of sufficiently small particle size so that at least about 99% by weight of the solids (dry basis) passes through a 150-mesh screen.
The matrix slurry containing 20% to 30% solids is withdrawn from holding tank (10), where solids are kept in suspension by constant agitation, and pumped by pump means 11 through conduit 12 to a high pressure super cyclone 14. The super cyclone is a 48-inch cyclone which is operated at feed pressures in the range of from 50 psig. to 80 psig., to prevent or inhibit losses of 150-mesh phosphate particles and maintain the percent solids in the overflow from said cyclones below 10% solids at about 50 psig. or below about 12% at 70 psig.
In the present process, overflow from cyclone 14 is generally discharged under pressure which may be sufficient to move the slimes through pipeline to the settling area without additional pump support. Location of the waste disposal area adjacent to or near the active mining operation and the use of piping arrangements which utilize gravitational forces help to achieve disposal of the slimes with minimum equipment and little, if any, additional electrical power.
The underflow from cyclone 14 is a dewatered-deslimed matrix having a solids concentration in excess of 65%. This dewatered-deslimed matrix is deposited wet upon a continuous belt 21 and transported on the belt to a matrix reslurry tank 22 located in the immediate vicinity of the ore dressing plant.
When the continuous belt is operated over extended distances and over terrain wherein the belt 21 is necessarily inclined or declined about 2° or more from level for a distance of several hundred feet or more, it is critical to dewater the matrix to at least 65% solids, and preferably to 75% solids concentration. It has been found that matrix having 65% or more solids can be successfully carried up to 2° to 3° grades for extended distances. However, when the solids content is reduced below about 65% and the wet matrix is transported under the stated conditions, washouts of the matrix on the belt can occur. Lower solids concentration in the wet matrix might be tolerated when the belt is operated over level terrain.
To deal with dewatering of the deslimed matrix on the belt 21, we have found it advantageous to flatten the belt at several locations, preferably on level terrain, along the transport route. This procedure permits any accumulation of water separated from the matrix to drain from the belt at sites where said belt is flattened.
Reslurried matrix from holding tank 22 is pumped by pump means 23 to the washer 24, the first stage of a conventional ore dressing process in which the deslimed matrix is washed, sized by screening, scrubbed, dewatered, conditioned and subjected to a flotation treatment where sand tailings are separated from the mineral values.
in accordance with the present process, a slurry of tailings 25 from the flotation treatment, is pumped by pump means 26 to a cyclone 27 where water is removed and recycled to the plant water holding pond. Dewatered tailings 28 from cyclone 27 are deposited on the returning strand of the continuous belt 21 and transported by belt 21 to a tails reslurry tank 29 at the intermediate station.
This arrangement reduces horsepower requirements for transport of both ore and tailings by a more efficient system and combines tails and matrix conveying into one unit. Reslurried tails from holding tank 29 are pumped by pump means to the waste disposal area where the slurry is sprayed over slimes which have settled to a solids concentration of from 10% to 25% solids.
Continuous land reclamation is thus achieved in accordance with the processes of the above-mentioned Cook et al. and Lassiter Patents.
FIG. 2 illustrates a variation of the ore processing method which is especially designed for the treatment of ores found to contain a high percentage of mudballs. This method involves mining and treatment of the matrix in about the same manner as described for the process of FIG. 1. The process differs in one material way, and that is installation of a sonic mudball disintegrator in the matrix slurry delivery system, between the pit pump 2 and the grizzly 4. In this process, the matrix slurry 3 from pumps 2 is introduced into a vessel equipped with transducers for generating sonic vibrations at frequencies as high as 100 cycles per second in the slurry to cause compacted clays or mudballs to be broken up or disintegrated, thus freeing entrapped phosphate particles.
Apparatus for generating and transmitting sonic vibrations in liquids, slurries, and the like, are described for example in U.S. Pat. to A. G. Bodine (No. 3,153,530; No. 2,960,317 and No. 3,682,511) and R. O. Speer (No. 3,811,623).
After subjecting the slurry 3 to sonic vibration treatment, the slurry is deposited on the grizzly 4 for scalping off any plus 3-inch material which remains in the slurry; as for example, rocks, wook, and the like. Treatment of the underflow from grizzly 4 is as described with reference to the process of FIG. 1.
While the continuous belt 21 is shown only schematically in FIGS. 1 and 2, FIGS. 3, 4 and 5 are provided to illustrate some details of a continuous belt system preferred in the practice of the present invention.
The system transport between the intermediate station and the ore processing plant comprises a flexible radial steel belt, reinforced longitudinally by steel cables embedded in the edges thereof. Power is transmitted to the belt by pneumatic tires working in pairs at the drive modules. Each drive module employs two pairs of drive wheels 31, one pair disposed at either edge of the radial steel belt, two pairs of free-wheeling pressure tires 32 disposed above said drive wheels on the opposite side of the upper strand of the belt, and two pairs of rubber-covered pressure rolls 33 disposed under said drive wheels, below the lower strand of the belt. The tires squeeze the edges of the belt, and as they turn the belt moves forward. The return strand of the belt is similarly powered as it is squeezed between the drive tires and the rubber-covered pressure rolls. Thus, the driving force applied at each module to both the primary belt and the return strand is uniform and synchronized.
Drive modules are spaced, as needed, along the length of the belt, and power for operating each drive module is furnished by a relatively low horsepower electric motor 34 at each module.
Between the drive modules, the belt is supported by several suspended idler support units (FIG. 3), spaced as needed along the length of the belt. Each idler unit comprises rollers 36 mounted in a frame 37 which is suspended at either end by cable means 38 mounted on adjustable supports 39. Each idler unit is equipped with a central support roller which supports the center of the belt and with two adjustable side or trough rollers which can be elevated as shown in FIG. 3 to support the sides of the belt and to form the belt into a "U"-shaped trough. The adjustable side rollers lend flexibility to the conveyor system. They can be lowered to permit flattening of the belt at selected locations. As indicated previously this arrangement is particularly advantageous for handling wet matrix, since it permits water which separates from the matrix while in transit to be drained from the belt.
In practice, the return strand of the belt is carried by similar idler supports, and when it is used to return wet tailings the same technique of flattening the lower section of the belt can be used to drain excess water which separates from wet trailings on the belt.
Also, in practice we have found it essential when using the intermediate conveyor system for the simultaneous transport of both matrix and tailings, to use the same surface of the belt in contact with both materials. This is achieved by providing means for twisting the return strand at each end of the conveyor system. The flexible belt is passed downward around horizontal rolls at the matrix discharge end of the system to reverse the direction of the belt. Before the lower section reaches the point for loading on tailings, the belt is twisted 90° onto vertical rolls, and then twisted another 90° onto horizontal rolls to complete a 180° twist at the beginning of the lower section. This procedure is reversed at the beginning of the upper section before the upper section reaches the matrix loading point at the mine area.
EXAMPLE 1
Two 48-inch cyclones having 10-inch apex openings are used in tests to determine feed solids concentrations and feed pressures required to achieve satisfactory desliming and dewatering of phosphate matrix slurry from the mine by the cyclones. In these tests, the cyclones are operated at 50 and 70 psi. feed pressures. At 50 psi. the slurry feed rate to the cyclones is maintained at about 10,000 gallons per minute, and at 70 psi. the feed rate is about 13,000 gallons per minute.
The solids concentration in the cyclone feed is varied between about 15% and 35% solids, and determinations of solids content are determined for both overflow and underflow at all pressures and solids concentrations. Data obtained are tabulated in Table 1. The tests indicate that solids concentration in the slurry feed to the cyclone should be maintained between about 20% and 30% in order to obtain a dewatered-deslimed matrix having a solids concentration between about 65% to 77%. Matrix from these tests was deposited on the continuous belt, shown as 21 in FIG. 1, and transported to the reslurry tank 22. Matrix having less than 65% solids when transported on the belt caused splash and deposition problems in loading the belt and washouts during belt transport up a 3% grade; whereas, matrix having 65% or more solids was satisfactorily deposited on the belt and transported to the reslurry tank.
TABLE I______________________________________Matrix Cyclone Test(Two 48-Inch Cyclones at 50 psi.)(10-Inch Apex Opening) (Feed Rate 10,000 gpm) Overflow Under- % % Losses TPH FlowΔP at Solids Sol- +150-mesh %Test Entry (Feed) ids per 1000 gpm Solids Remarks______________________________________A 50 psi. 15 4.4 0.1 57 Underflow Solids to lowB 50 psi. 20 6.0 0.3 65 ↑C 50 psi. 25 8.1 0.5 75 OperatingD 50 psi. 25 8.1 0.5 75 RangeE 50 psi. 30 10.0 1.2 76 ↓F 50 psi. 35 20.0 24.0 77 Cyclone ChokingG 70 psi. 15 4.8 0.1 59 Underflow Solids to lowH 70 psi. 20 6.9 0.2 66I 70 psi. 25 8.5 0.7 76 OperatingJ 70 psi. 25 8.5 0.7 76 RangeK 70 psi. 30 10.6 2.5 77L 70 psi. 35 20.0 30.0 77 Cyclone Over- loaded______________________________________
EXAMPLE 2
Sonic Mudball Disintegration Tests
The purpose of the test was to demonstrate the use of vibration or sound vibration to break up clay mudballs in phosphate pebble.
Sonic Unit
Standard Bodine sound drive unit driven by a 25 HP motor, coupled to a 51/4 inches inside diameter pipe approximately 4 feet long. Amplitude and cycles were variable but run at 96 cycles per second at the amplitude chosen by the operator. Fractional horsepower (1 HP) was required for the tests, but the unit is equipped with a large motor for other laboratory test purposes.
Procedure
Mixtures of plus 3-inch mudballs and muddy pebble from actual phosphate ore slurries [supplied by Brewster] were prepared as shown below. This mixture was placed in the 51/4 inches ID tube and sonically vibrated for the time shown. After treatment the sample was removed and examined for clay mudballs. In test 8, a 41/4 inches OD steel insert (carrot) was added with the feed sample. In test 9, a 31/2inches OD steel insert was added with the feed sample. In tests 6, 7, 10, 11 and 12, a 41/2 inches diameter steel insert was added inside the the tube with the feed. The sound drive was turned on and run for the time shown.
Conclusions
1. Clay mudballs can be dispersed in water by exposure to sonic vibrations.
2. Ten seconds exposure is required for 70-80% dispersion of mudballs with a 41/2 inches diameter insert.
3. Twenty seconds exposure is required for complete dispersion of mudballs with a 41/4 inches diameter insert.
4. Ten seconds exposure is required for complete dispersion of mudballs with a 41/4 inches insert when an equal amount of fine feed is added.
5. Sufficient water is required -- not over 66% -- to disperse the clay.
Data obtained are reported in Table II below.
TABLE II__________________________________________________________________________ CyclesTest % Sample Time perNumberFeed Mixture Solids Size Exposed Second Observations__________________________________________________________________________1 5 lbs Muddy Pebble 35 2 25% of mudballs dispersed1 lb Mudballs2 1 lb Mudballs 35 5 50% of mudballs dispersed3 1 lb Mudballs 35 10 75% of mudballs dispersed4 1 lb Mudballs 35 20 90% of mudballs dispersed5 5 lbs Mudballs 80 5 lbs 20 96 One-half mudballs crushed; water needed for dispersion6 22 lbs Muddy Pebble 50 25 lbs 10 96 Overloaded tube; water not3 lbs Mudballs dispersed7 3 lbs Mudballs 50 25 lbs 20 96 Overloaded tube; water not dispersed8 41/2 lbs Muddy Pebble 35 5 lbs 10 96 Crushed pebble and mud1/2 lb Mudballs9 41/2 lbs Muddy Pebble 35 5 lbs 10 96 One-half mudballs dipsersed1/2 Mudballs10 41/2 lbs Muddy Pebble 35 5 lbs 10 96 Three-quarters mudballs1/2 lb Mudballs dispersed11 41/2 lbs Muddy Pebble 35 5 lbs 20 96 All mudballs dispersed1/2 lb Mudballs12 11/2 lbs Muddy Pebble 35 31/2 lbs 10 96 All mudballs dispersed11/2 lbs Crushed Pebble1/2 lb Mudballs__________________________________________________________________________
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A method of processing hydraulically mined ore slurries containing, in addition to the valuable ore, substantial quantities of contaminating argillaceous material and silica, involving initially separating the argillaceous material from the ore slurry while concomitantly concentrating said slurry to at least 65% solids content, depositing the wet concentrate thus formed on a continuous belt and conveying said wet concentrate via said belt to a beneficiation plant for further treatment.
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BACKGROUND OF THE INVENTION
Injection nozzles are known, both in the form of partially squeezable hole-type nozzles and in the form of annular gap nozzles. In the known gap nozzles, a needle, which is axially adjustable, is arranged concentrically in the nozzle housing, and, together with the concentric nozzle opening of the nozzle housing, defines a variable gap with respect to the injection mixing chamber. This gap can be altered by means of adjustable stops. The reaction components to be mixed flow from the nozzle opening or the annular gap into an injection mixing chamber in which they are mixed together. The energy required for injection mixing is substantially dependent on the rate of flow, the viscosity, the solubility and the metering ratio of the reaction components. In addition to the distance and the position of the injection nozzles relative to each other, the shape and, in particular, the cross-sectional area of the nozzle openings (or the cross-section of flow) have a great influence on the degree of mixing. The nozzle openings (or their cross-sectional areas) are adjusted manually depending upon the rate of flow and viscosity of the reaction components passing therethrough. Adjustment is usually carried out after a largely subjective judgment of the degree of mixing. Such adjustments can be conducted, for example, by axial adjustment and fixing of the nozzle needle.
It has proved helpful to use the hydraulic pressure which has built-up between the metering pump and injection nozzle as a measure of the mixing energy available for injection mixing purposes. The minimum pressure needed for mixing is dependent on the above-mentioned parameters. Such pressure normally lies between 50 and 150 bar, but can reach 350 bar or even more in some cases. Since deviations from the optimum operating pressure in the metering system impair the degree of mixing, a constant, securely adjusted metering rate and viscosity of the reaction components and also a constant, securely adjusted opening cross-sectional area of the associated injection nozzles are preferably adopted during injection mixing.
A significant disadvantage of this mode of operation is that it is not possible to effect significant change in the metered quantity of reaction components per unit time. This change may be desirable in order to adapt the metered quantity of the resulting multi-component reaction mixture optimally to the geometric conditions within the mold cavities during the mold filling process.
The object of the invention is to allow a significant change in the metered quantity of reaction components per unit time, adapted to the geometric conditions within the mold cavity, of multi-component reaction materials, which may be highly reactive, during a mold-filling process even when using injection mixers, without impairing the mixed product of the reaction mixture produced in the injection mixers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an injection mixing device with manually adjustable injection nozzles and a control and ejection piston which controls advance and return.
FIG. 2 shows an injection mixing device with hydraulically actuatable injection nozzles in which the advance and return are controlled by means of the injection nozzles.
DESCRIPTION OF THE INVENTION
The above objects are achieved according to the instant invention by:
(a) altering the metered quantity of reaction components per unit time during the injection process, and
(b) altering the cross-sections of injection into the mixing zone synchronously with the change in the metering rate.
This expedient permits the process of charging the flowable reaction mixture into the mold cavity to be adapted sufficiently carefully to make it possible to avoid the occurrence of serious defects involving air inclusions, which lead to undesirable bubble formation. The invention thus allows, for the first time, the introduction of the reaction mixture to be optimized over the duration of the filling time during injection mixing by a continuous method. The entry speed of the components into the mixing zone is preferably kept constant. Constant mixing conditions are thus also achieved.
The device of the invention comprises storage containers, from which feed pipes lead, via metering pumps whose metering capacity is adjustable, to a mixer head and merge via injection nozzles into a mixing chamber, the mixing chamber having an outlet opening. The novelty lies in the fact that:
(a) the injection nozzles have axially movable nozzle needles and in that
(b) each nozzle needle is provided with at least two adjustable stroke-limiting stops.
Each predetermined position of the stops corresponds to a specific position of the nozzle needle at the moment it rests against the stop and thus characterizes a specific opening cross-section of the nozzle corresponding to a previously determined metering rate. This allows the corresponding position of the nozzle needles to be adjusted by the predetermined stops. The desired opening cross-sections of the nozzles are thus controlled. The stops can be, for example, manually adjustable. Necessarily they may have to be adjusted during the mixing process.
In a preferred embodiment of the device, a control instrument is used. This instrument has pulse carrying lines for adjusting the output of the metering pump, the lines leading to the drive means thereof and to servomotors in order to actuate control valves for controlling an ejection piston, the injection nozzle and the stops. The feeding of a program into the control instrument allows the mixing process to be controlled and adjusted as desired. An optimized program can thus be introduced for each reaction system.
The control is effected as a function of the metered quantity of reaction components per unit time, for example, by means of the stroke speed or number of strokes of the associated metering pump or as a function of the hydraulic pressure in the metering system. The ability to control and adjust the process to differing molds is possible due to the adjustability of the stops, preferably by means of servomotors. Such measures are particularly advantageous in the mass-production of molded articles of differing size and geometry on one production line.
The invention allows at least two injection nozzles for at least two reaction components to be operated synchronously. The invention also allows a single injection nozzle to be reversed thereby changing the metering rate of only one of the reaction components. In the first case, it is also possible to carry out a synchronous change in the metering rate of all reaction components while keeping the metering ratio constant between the reaction components. Perfectly mixed products result. For example, during the mold filling process and, more specifically while changing the metering rate, a maximum change down to about 20% of a predetermined maximum metering rate is possible.
In the second case, the method allows the controlled alteration of the metering ratio, for example, of polyurethane reaction components relative to each other during one shot. This shift in the "index number" allows a change in the properties to be achieved within a molded article. The invention can be applied to devices whose mixer head has a control and/or cleaning piston as well as to devices whose mixer head is provided with injection nozzles which control the return flow.
Both the structural design of the stops and the control thereof gives the routineer the choice of many different embodiments.
The device according to the invention is illustrated schematically by two embodiments and is described in more detail below.
In FIG. 1, the device comprises storage containers 1,2. Feed pipes, 3,4, in which metering pumps 5,6 are placed, lead from the containers to injection nozzles 7,8 which merge into a mixing chamber 10 arranged in a mixer head housing 9. A control and ejection piston 12 which can be actuated by means of a hydraulic drive means 11 and which has circular guide grooves 13,14 is guided in the mixing chamber 10. The ejection piston 12 is shown in the mixing position in its left-hand half and in the ejection position in its right-hand half. In the ejection position, the circular guide grooves 13,14 are connected via return pipes 15,16 to the storage containers 1,2.
The injection nozzle 7 for the first component comprises the nozzle housing 17, the nozzle needle 18 and the nozzle opening 19 as well as the hydraulic drive means. The hydraulic drive means consists of a piston 20 which can be charged on both sides and is connected to the nozzle 18, and the hydraulic chamber 21, in addition to feed pipes 22,23. The nozzle needle 18 is provided at its downstream end with an adjusting nut acting as a stop 24, by means of which it is possible to adjust the minimum cross-section of flow to the nozzle opening 19. The adjusting nut 24 lies against the housing edge 25 in the position shown. The nozzle housing 17 is widened to an extension 26 in which a hydraulic unit consisting of piston 27 and cylinder 28 is arranged. The feed pipes are designated by 29,30. The piston rod 31 is guided outwards on both sides by the extension 26 and bears adjusting nuts acting as adjustable stops 32,33 at both ends. The adjusting nuts strike the housing edges 34,35. The adjusting nut 32 serves to define the middle position of the nozzle needle 18 with an associated middle cross-section of flow with charging of the piston 27 via the feed pipe 29 and the piston 20 via the feed pipe 23. The maximum stroke, adjusted by means of the adjusting nut 33, with the largest opening cross-section is achieved by charging the piston 20 also via the feed pipe 23, but the piston 27 via the feed pipe 30. The injection nozzle 7 is thus provided with three stops 24, 32, 33.
The injection nozzle 8 for the second component is constructed in a different manner only in order to illustrate an alternative possible embodiment. It comprises the nozzle housing 36, the nozzle needle 37 and the nozzle opening 38 as well as the hydraulic drive means consisting of a piston 39 (which is connected to the nozzle needle 37 and can be charged on both sides), and the hydraulic chamber 40 in addition to feed pipes 41, 42. The nozzle needle 37 is provided at its downstream end with an adjusting nut acting as a stop 43 with which the minimum cross-section of flow to the nozzle opening 38 can be adjusted. The stop nut 43 strikes against housing edge 44 in the illustration. The nut 45 serves to secure the adjusting nut 43. The stop nut 43 determines the minimum cross-section of flow. An adjusting screw with counter nut 48 is held coaxially as stop 47 in an extension 46 of the nozzle housing 36. The desired maximum entry cross-section can be adjusted by means thereof.
The hydraulic piston 27 should be provided with a larger area relative to the pressure area of the piston 20 at the same hydraulic control pressure for all control processes on the injection nozzle. Alternatively, it should be charged with a higher pressure than the piston 20 so that the nozzle needle 18 can be held in the central position.
In FIG. 2, the device consists of storage containers 201,202. Feed pipes 203,204, in which metering pumps 205,206 are placed, lead from them to injection nozzles 207,208 which merge into a mixing chamber 210 arranged in a mixer head housing 209. An ejection piston 212 which can be moved by means of a hydraulic drive means 211 is guided in the mixing chamber 210.
The hydraulic drive means 211 has a hydraulic piston 213 which can be charged on both sides at its other end, a hyraulic chamber 214,215 being located on each side. A suction pipe 217 leads from a hydraulic fluid reservoir 216 to a hydraulic pump 218 from which a pressure pipe 219 continues. A control valve 220 is connected to the pump 218 via a pipe 221. The control valve 220 is connected in such a way that the pipe 221 communicates via a pipe 222 with the hydraulic chamber 214. A pipe 223 leads from the chamber 215 to the valve 220. A pipe 224 leads from the valve 220 to the return pipe 225 which merges into the reservoir 216. In the other position (not shown) of the control valve 220, the pipe 221 communicates with the pipe 223 and the pipe 222 with the pipe 224 in order to charge the chamber 215 so that the contents of the mixing chamber 210 are ejected by advance of the ejection piston 212.
The injection nozzle 207 for the first component comprises the nozzle housing 226, the nozzle needle 227 and the nozzle opening 228 as well as the hydraulic drive means 229 consisting of a piston 230 (which communicates with the nozzle needle 227 and can be charged on both sides), and hydraulic chambers 231,232 (being arranged on both sides thereof).
The nozzle housing 226 has a coaxial adjustable screw 233 in which is guided, coaxially to the nozzle needle 227, a stop 234 which is designed as a needle and whose downstream end has a hydraulic piston 235 which can be charged on both sides and forms, together with the hydraulic chambers 236,237, the hydraulic drive means 238. The minimum stroke of the nozzle needle 227 is set by adjusting the screw 233. The maximum stroke of the nozzle needle 227 can be adjusted by means of another adjusting screw 239.
The component supplied via the pipe 203 is circulated via the annular space 240 provided between the nozzle needle 227 and the nozzle housing 226 into the return pipe 241 which merges into the storage container 201. By reversing the nozzle needle 227 by means of the hydraulic drive 229, the nozzle needle 227 travels against the stop 234, seals the annular chamber 240 and thus releases the nozzle opening 228 so that the component can flow into the mixing chamber 210.
The injection nozzle 208 for the second component is constructed in a similar manner and comprises the nozzle housing 242, the nozzle needle 243 and the nozzle opening 244 as well as the hydraulic drive means 245. The hydraulic drive means consists of a piston 246 (which communicates with the nozzle needle 243 and can be charged on both sides), and hydraulic chambers 247,248 (being arranged on both sides thereof). The nozzle housing 242 has an adjustable screw 249 in which a stop needle 250 is guided coaxially to the nozzle needle 243. The rear end of the stop needle 250 carries a hydraulic piston 251 which can be charged on both sides, and which together with the hydraulic chambers 252, 253, forms the hydraulic drive means 254. The minimum stroke of the nozzle needle 243 is set by adjusting the screw 249. The maximum stroke of the nozzle needle 243 can be set by means of another adjusting screw 255. The component supplied through the pipe 204 is circulated via the annular chamber 256 provided between the nozzle needle 243 and the nozzle housing 242 into the return pipe 257 which merges into the storage container 202. By reversal of the nozzle needle 243 by means of the hydraulic drive means 245, the nozzle needle 243 travels towards the stop 250, seals the annular chamber 256 and thus clears the nozzle opening 244 so that the component can enter the mixing chamber.
A pipe 258 containing a pressure-reducing valve 259 branches from the pressure pipe 219 and leads to a control valve 260. A branching pipe 261 leads from it to the hydraulic chambers 232,248. A combining pipe 262 leads from the hydraulic chambers 231,247 to a control valve 260. The control valve is connected via a pipe 263 to the return pipe 225. If the hydraulic chambers 231,247 are to be charged, so as to reverse the nozzle needles 227,243, then the control valve 260 switches the pipe 258 together with the pipe 262 and simultaneously connects the pipe 261 to the pipe 263.
Finally, an additional branch pipe 264 leads from the pressure pipe 219 to a control valve 265. A branching pipe 266 leads from it to the hydraulic chambers 236,253. A combining pipe 267 leads from the hydraulic chambers 237,252 to the control valve 265, from which a branch pipe 268 leads to the return pipe 225. If the hydraulic chambers 236,253 are to be charged, in order to allow the minimum position of the nozzle needles 227,243, then the control valve 265 connects the pipe 264 to the pipe 266, and the pipe 267 to the pipe 268 by switching over. An overflow pipe 269 in which an adjustable pressure overflow valve 270 is arranged leads back into the reservoir 216.
The control valve 220 consequently actuates the ejection piston 212. The control valve 260 actuates the nozzle needles 227,243 of the forced control injection nozzles 207,208 to "circulate" and to "mix". Finally, the control valve 265 actuates the stop needles 234,250 to adjust the desired stroke width of the nozzle needles 227,243. The screws 233,249 are held adjustably in the nozzle housings 226,242 by means of a screw thread (not numbered) so that the stroke width of the nozzle needles 234,243 can be adjusted for the minimum position.
A control instrument 271 allows a program to be preset. Accordingly, pulses will be emitted at desired moments by means of time clocks contained in the control instrument 271. Pulses are transmitted from the control instrument via the pulse line 272 to the drive means 273 of the metering pump 205, via the pulse line 274 to the drive means 275 of the metering pump 206, via the pulse line 276 to the servomotor 277 of the control valve 220, via the pulse line 278 to the servomotor 279 of the control valve 260, and via the pulse line 280 to the servomotor 281 of the control valve 265.
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The invention relates to a method and a device for producing a solid-forming or foam-forming flowable reaction mixture by metered injection of flowable reaction components into a mixing zone from which the finished reaction mixture is discharged.
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CROSS-REFERENCE TO PROVISIONAL APPLICATIONS
This application claims priority from provisional patent application Ser. No. 60/126,373, filed Mar. 26, 1999, the entire disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to lubricant compositions for lubricating magnetic data, particularly rotatable magnetic recording media, such as thin film magnetic disks having textured surfaces and a lubricant topcoat for contact with cooperating magnetic transducer heads.
BACKGROUND OF THE INVENTION
Thin film magnetic recording disks and disk drives are conventionally employed for storing large amounts of data in magnetizable form. In operation, a typical contact start/stop (CSS) method commences when a data transducing head begins to slide against the surface of the disk as the disk begins to rotate. Upon reaching a predetermined high rotational speed, the head floats in air at a predetermined distance from the surface of the disk, where it is maintained during reading and recording operations. Upon terminating operation of the disk drive, the head again begins to slide against the surface of the disk and eventually stops in contact with and pressing against the disk. Each time the head and disk assembly is driven, the sliding surface of the head repeats the cyclic operation consisting of stopping, sliding against the surface of the disk, floating in the air, sliding against the surface of the disk, and stopping.
For optimum consistency and predictability, it is necessary to maintain each transducer head as close to its associated recording surface as possible, i.e., to minimize the flying height of the head. Accordingly, a smooth recording surface is preferred, as well as a smooth opposing surface of the associated transducer head. However, if the head surface and the recording surface are too flat, the precision match of these surfaces gives rise to excessive stiction and friction during the start up and stopping phases, thereby causing wear to the head and recording surfaces, eventually leading to what is referred to as a “head crash.” Thus, there are competing goals of reduced head/disk friction and minimum transducer flying height.
Conventional practices for addressing these apparent competing objectives involve providing a magnetic disk with a roughened recording surface to reduce the head/disk friction by technique generally referred to as “texturing.” Conventional texturing techniques involve mechanical polishing or laser texturing the surface of a disk substrate to provide a texture thereon prior to subsequent deposition of layers, such as an underlayer, a magnetic layer, a protective overcoat, and a lubricant topcoat, wherein the texture on the surface of the substrate is intended to be substantially replicated in the subsequently deposited layers.
A typical longitudinal recording medium is depicted in FIG. 1 and comprises a substrate 10 , typically an aluminum (Al)-alloy, such as an aluminum-magnesium (Al—Mg)-alloy, plated with a layer of amorphous nickel-phosphorus (NiP). Alternative substrates include glass, glass-ceramic materials and graphite. Substrate 10 typically contains sequentially deposited on each side thereof a chromium (Cr) or Cr-alloy underlayer 11 , 11 ′, a cobalt (Co)-base alloy magnetic layer 12 , 12 ′, a protective overcoat 13 , 13 ′, an a lubricant topcoat 14 , 14 ′. Cr underlayer 11 , 11 ′ can be applied as a composite comprising a plurality of sub-underlayers 11 A, 11 A′.
The protective overcoat desirably possesses high durability, density and hardness to protect the underlying magnetic layer providing wear resistance and encouraging durability of the magnetic recording medium arrangement. Typically, a thin film of zirconium oxide, silicon oxide or carbon is used as a protective overcoat.
Chromium underlayer 11 , 11 ′, Co-base alloy magnetic layer 12 , 12 ′ and protective overcoat 13 , 13 ′ are usually deposited by sputtering techniques performed in an apparatus containing sequential deposition chambers. A conventional Al-alloy substrate is provided with a NiP plating, primarily to increase the hardness of the Al substrate, serving as a suitable surface to provide a texture which is substantially reproduced on the disk surface.
In accordance with conventional practices, a lubricant topcoat is uniformly applied over the protective overcoat to prevent wear between the disk and head interface during drive operation. Excessive wear of the protective overcoat increases friction between the head and disk, thereby causing catastrophic drive failure. Conversely, excess lubricant at the head-disk interface causes high stiction between the head and disk. If stiction is excessive, the drive cannot start and, likewise, catastrophic failure occurs.
The drive towards ever increasing recording density, and faster data transfer rates and the resulting smoother disk surfaces and lower flying heights, has served as an impetus for the development of new lubricants to serve as a lubricating topcoat overlying the protective overcoat. Such lubricants must perform a variety of different purposes requiring diverse characteristics and attributes. For example, the lubricant forming the topcoat is preferably chemically inert, possesses a low vapor pressure, low surface tension, high thermal stability, stability under high shear stress and good boundary lubrication properties. Moreover, it is critical that the lubricant tightly adheres to the underlying surface over the lifetime of the magnetic recording media.
The entire disc surface of a magnetic recording disc, however, is not ideal for reading and writing data. In particular, disc surfaces have asperities, i.e. protrusions on surfaces of the disks, which interfere with the flying characteristics of the data head, as well as the read and write operations of the data head. In operation, the head can come into contact with asperities while the head flies above the surface of the disc. Potentially, this undesirable contact can cause data written to a particular location on a disc to be lost. In an effort to alleviate such occurrences, manufactures commonly burnish the surfaces of disks to reduce asperities located thereon. Typical burnishing processes, however, cause contamination of ceramic oxides, such as aluminum oxide, on the disk's surface which can catalyze the decomposition of the lubricant topcoat layer resulting in reduced tribological properties.
Several classes of lubricants may satisfy some of the desired properties. Among the many lubricants available, liquid perfluoropolyethers (PFPE) are the most utilized for forming topcoat lubricants on magnetic recording media. PFPE's have been reported for use as lubricating magnetic media in, for example, U.S. Pat. No. 3,778,308. PFPE having a variety of polar end-groups are known (see, e.g. U.S. Pat. Nos. 3,810,874; 4,085,137 and 4,647,413) and have been used in an attempt to improve adhesion of the lubricant to the magnetic medium (see, e.g. U.S. Pat. Nos. 4,268,556; 4,696,845; 4,889,939; 5,128,216). Their preparation has also been widely reported (see, e.g., U.S. Pat. Nos. 3,810,874 and 5,506,309)
Typical conventional lubricants, such as perfluoroalkylpolyether (PFPE) fluids such as Fomblin Z-DOL, Fomblin TX, and Fomblin Z-Tetraol, etc., generally have 2-4 polar groups at either end of a linear perfluorinated polyalkylether backbone. The functionalized end groups are considered necessary to provide direct bonding, and thus, improved adhesion of the lubricant topcoat to the recording media. Polar functional groups, however, are not necessarily chemically inert and consequently, such conventional lubricants may disadvantageously undergo chemical reactions prior to their application or while on the magnetic medium tending to decrease their adhesion to the disk surface. Undesirable chemical reactions further include degradation of the lubricant itself. Contamination by Lewis acids, such as aluminum oxide, on magnetic recording media further promote degradation of the lubrications.
Thus, a significant factor in the performance of a lubricant topcoat is the ability of the lubricant to resist decomposition over time, particularly decomposition by acid catalysis. Lubricants that can adhere to the surface of magnetic media and resist degradation provide improved tribology and durability.
In view of the criticality of the lubricant topcat, there is a continuing need for improved adherence of the lubricant to the magnetic recording medium, particularly to a carbon-based protective overcoat. There also exists a need for a lubricant topcoat providing improved durability, stiction and wear performance, particularly under conditions of high stress, temperature, and humidity.
SUMMARY OF THE INVENTION
An advantage of the present invention is a lubricant composition with improved resistance to degradation, particularly, resistance to thermal and acid decomposition.
Another advantage of the present invention is a magnetic recording medium comprising a lubricant composition exhibiting high stability to degradation.
Additional advantages and other features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the invention. The advantages of the invention may be realized and obtained as particularly pointed out in the appended claims.
According to the present invention, the foregoing and other advantages are achieved in part by a magnetic recording medium comprising a magnetic layer and a lubricant composition on the magnetic layer, wherein the lubricant composition comprises a first fluoropolyether and a decomposition inhibiting amount of a second fluoropolyether having at least one nitrogen containing end group.
According to embodiments of the present invention, the nitrogen containing end group of the lubricant molecule comprises one or more amine and/or amide groups. It is advantageous to have one or more amine and/or amide groups as end-groups on the second fluoropolyether to reduce catalytic degradation of the lubricant composition.
In an embodiment of the present invention, the second fluoropolyether has the following formula:
Z—(A) q
wherein Z is a fluorinated polyalkylether; A is an amine or amide group; and q is an integer of 1 to about 4.
In an embodiment of the present-invention, Z is a perfluoropolyether comprising a plurality of —(C a F 2a O) n — repeating units, wherein subscript a is independently in each such units an integer of from 1 to about 10 and n is an integer from 2 to about 100 and A is a NR 1 R 2 or CONR 1 R 2 group wherein R 1 and R 2 are independently H, substituted or unsubstituted alkyl, or substituted or unsubstituted aryl groups.
Another aspect of the present invention is a method of manufacturing a magnetic recording medium. The method comprises forming a magnetic layer on a substrate; and forming a lubricant topcoat on the magnetic layer, wherein the lubricant topcoat comprises a first fluoropolyether and a decomposition inhibiting amount of a second fluoropolyether having a nitrogen containing end-group.
Another aspect of the present invention is a lubricant composition comprising a first fluoropolyether and a decomposition-inhibiting amount of a second fluoropolyether, wherein the second fluoropolyether has a nitrogen containing end-group.
Embodiments include a lubricant composition wherein the first fluoropolyether is a perfluoropolyether; the second polyether is a fluoropolyether having an amide group, such as a CONR 1 R 2 group wherein R 1 and R 2 are independently H, substituted or unsubstituted alkyl, or substituted or unsubstituted aryl groups; and the composition comprises no less than about 20 weight percent (wt. %) of the second fluoropolyether.
Additional advantages of the present invention will become readily apparent to those having ordinary skill in the art from the following detailed description, wherein the embodiments of the invention are described, simply by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the present invention can best be understood when read in conjunction with the following drawings, wherein:
FIG. 1 schematically depicts a magnetic recording medium structure to which the present invention is applicable.
FIGS. 2 and 3 represent thermogravimetric analytical results comparing a conventional lubricant to the effectiveness of the inventive lubricant composition.
FIG. 4 graphically illustrates the thermal stability of a lubricant composition of the present invention.
DESCRIPTION OF THE INVENTION
The present invention is directed to novel lubricant compositions which can be advantageously employed as lubricant topcoat on magnetic recording media with increased resistance to degradation. It as been found through experimentation that the lubricant endgroup has an effect on the thermal stability and/or susceptibility of a fluoropolyether lubricant to degradation, particularly degradation due to acid catalyzed cleavage.
For example, it was discovered that the more acidic the endgroup on the fluoropolyether lubricant, the lower the thermal stability was observed for the lubricant. It was then discovered that fluoropolyethers having a basic functionality, or more particular, fluoropolyethers having a nitrogen containing end-group are less prone to acid catalyzed decomposition and have superior thermal stability in an environment with Lewis acids, such as aluminum oxides, as found on the surface of magnetic medium. It was further discovered that by admixing a first fluoropolyether with a second fluoropolyether substituted with a nitrogen containing end-group, the admixture also exhibited superior thermal stability when exposed to acids in general.
By a nitrogen containing end-group, it is meant that the second fluoropolyether has a group or groups on one or more ends that can inhibit acid catalyzed degradation of the lubricant composition. Such groups can also be classified as either proton acceptors or having a pair of available electrons.
In accordance with the present invention, a lubricant composition is prepared by combining a first fluoropolyether, such as a convention PFPE, with a decomposition-inhibiting amount of a second fluoropolyether, such as a fluoropolyether having one or more terminal amines or amides. In an embodiment of the present invention, the second fluoropolyether is present in an amount of from about 20 weight percent (wt. %) to about 95 wt. %, e.g., from about 25 wt. % to about 60 wt. % in the lubricant composition.
Fluoropolyethers substituted with one or more amine or amide groups of the forgoing have the formula:
Z—(A) q
wherein Z is a fluoropolyether, e.g. a polyether comprising fluoroalkylether, fluoroarylether, perfluoroalkylether or perfluoroarylether repeating units with one to ten carbon atoms randomly or uniformity distributed along the backbone of the polymer; A is an amine or amide, e.g a NR 1 R 2 or CONR 1 R 2 group wherein R 1 and R 2 are independently H, substituted or unsubstituted alkyl or aryl groups; and q is an integer of 1 to about 4.
In an embodiment of the present invention, the second fluoropolyether is a perfluoropolyether amide. For example, where Z comprises a plurality of —(C a F 2a O) n — repeating units, wherein subscript a is independently in each such units an integer of from 1 to about 10 and n is an integer from 2 to about 100; and A is a —CONR 1 R 2 group wherein R 1 and R 2 are independently H, substituted or unsubstituted alkyl, or substituted or unsubstituted aryl groups.
First, fluoropolyethers of the inventive lubricant composition include homopolymers, random polymers or block polymers, i.e. the repeating units of the fluoropolyether may be the same or different. In an embodiment of the present invention, the first fluoropolyether of the lubricant composition is a perfluoroalkylether, such as a perfluoropolyalkylether substituted with one or more hydroxyl groups.
The second fluoropolyether of the inventive lubricant composition can be a homopolymer, random polymer or block polymer. For example, Z can be a fluorinated polyalkylether with different repeating units randomly distributed along the backbone of the polymer or distributed a a block of one type of repeat unit and subsequent blocks of different repeat units along the backbone of the polymer. The decomposition-inhibiting second lubricant can be completely fluorinated or partially fluorinated and can be linear or branched.
In an embodiment of the present invention, Z is a perfluoroalkylpolyether comprising a plurality of —(C a F 2a O) n — repeating units, wherein subscript a is independently in each such unit an integer of from 1 to about 10 and n is an integer from 1 to about 100.
A fluoropolyether having one or more amine or amide terminal groups of the present invention can be formed, for example, by derivatizing a variety of commercially available fluoropolyether lubricants, such as those conventionally employed to form lubricant topcoats on magnetic recording media. The second lubricant of the inventive composition can be prepared, for example, by combining a perfluoropolyether having a terminal carboxylic acid on either end thereof with, for example, a substituted or unsubstituted amine to yield a perfluoropolyetheramide terminated lubricant.
Alternatively, the lubricants having a nitrogen containing end-group can be prepared by fluorinating a hydrocarbon polyether having the end-group as such fluorination techniques are known.
Several specific examples of the decomposition-inhibiting lubricants according to the present invention are given in the table below.
TABLE
Lubricant
Chemical Structure
q
1
1
2
2
3
2
4
4
5
1
6
1
7
2
Where Z is —(CF 2 CF 2 O) n —(CF 2 O) m — and n an m are between 1 and about 100, e.g., approximately 10 to about 30.
The lubricant compositions of the present invention can be applied to a magnetic recording medium in any convenient manner as by dip coating the medium in a solution comprising the lubricant composition in a conventional organic solvent. The lubricant topcoat of the present invention can be applied to a magnetic recording medium, either directly on the magnetic layer or directly on a conventionally applied protective overcoat, particularly a carbon overcoat to form a substantially homogeneous topcoat lubricant, e.g., a topcoat which is free of any measurable disperse phase. In an embodiment of the present invention, the lubricant composition is dissolved in a conventional solvent, such as Freon, Vertrel XF or perfluorohexan (solvents available from Dupont), in a ratio of about 0.0001% to about 100% by (weight/weight), e.g. about 0.001% to about 1%. A typical magnetic recording medium, for example, a composite comprising a non-magnetic substrate having sequentially deposited on each side thereof an underlayer, a magnetic layer, and a protective carbon overcoat, is submerged in the solution containing the lubricant composition and then slowly withdrawn therefrom. In practicing the present invention, one can employ a convention lifter-type dipper to submerge the composite in the lubricant solution. One having ordinary skill in the art can easily optimize the duration of submergence and the speed of withdrawal to achieve a desired coating thickness.
To demonstrate the improved resistance to acid induced decomposition of the inventive lubricant compositions, thermogravimetric analysis was conducted on conventional lubricants and compositions comprising conventional lubricants with a fluoropolyether having a nitrogen containing end-group. In performing the experiment, about 25 mg of conventional Z-DOL lubricant having a number average molecular weight of about 4500 was mixed with 5 mg of Al 2 O 3 . The thermal stability of the conventional Z-DOL lubricant is shown in FIG. 2, where the convention lubricant decomposes at approximately 270° C.
For comparison, lubricant compositions comprising about 3 parts by weight of the same conventional Z-DOL lubricant with one part by weight of an amide lubricant shown in Table 1 was prepared by admixing the respective lubricants together. Then about 25 mg of the lubricant composition was mixed with about 5 mg of Al 2 O 3 and placed in a thermal gravimetric analyzer. As shown in FIG. 3, the thermal stability of the inventive lubricant compositions surpasses that of conventional Z-dol. The 1:3 lubricant compositions have a thermal stability of approximately 310° C.
FIG. 4 further demonstrates the benefit of the lubricant compositions of the present invention by graphically illustrating the decomposition-inhibiting effect of an amide lubricant. The graph demonstrates the thermal enhancement of an amide lubricant in a lubricant composition with a convention PFPE as a function of weight percent of the amide lubricant. As shown, admixing about 25 wt. % of an amide lubricant together with a convention PFPE lubricant improves the thermal stability of the lubricant composition from about 287° C. to about 305° C.
Solutions of the lubricant compositions of the present invention can be formed by simply dissolving the lubricant compositions of the present invention in a hydrofluorocarbon to produce a homogeneous solution. The prepared solution can then be easily applied to a magnetic recording medium as, for example, to form lubricant topcoat 14 in the magnetic recording medium depicted in FIG. 1 . In accordance with the present invention, the lubricant topcoat can be advantageously applied by submerging a disk in the lubricant solution for a sufficient period of time to form a lubricant topcoat on the disk and removing excess lubricant, as by hand wiping.
As previously disclosed, the lubricant solution in accordance with the present invention can be applied by hand wiping or mechanical wiping techniques after immersing a disk in a lubricant solution. A disk ready for application of a lubricant topcoat is soaked in the lubricant solution, removed from the solution and hand or machine wiped, as with a clean cotton wipe. In this manner, a homogeneous topcoat lubricant comprising the first and second lubricant having a thickness ranging from about 10 Å to about 100 Å can be obtained depending upon the formulation and wipe procedure.
The present invention is not limited to any particular type of magnetic recording medium, but can be employed in any of various magnetic recording media, including those wherein the substrate or a subsequently deposited layer has been textured, as by mechanical treatment or laser techniques, and the textured surface substantially reproduced on subsequently deposited layers. Thus, a lubricant composition prepared in accordance with the present invention, can be applied to form a topcoat, such as topcoat 14 on the magnetic recording media depicted in FIG. 1, but not necessarily limited thereto.
Only the preferred embodiment of the invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
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A lubricant composition comprising a first fluoropolyether and a second fluoropolyether having nitrogen containing end-group exhibits improved resistance to acid and thermal decomposition. Embodiments include a lubricant composition containing a perfluorinate polyalkylether admixed with a perfluorinated polyalkylether having amide terminal groups and applying the composition to the surface of a magnetic recording medium to form a homogeneous lubricant topcoat thereon.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2010 008 923.0 filed Feb. 23, 2010, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a directional valve for a respirator product.
BACKGROUND OF THE INVENTION
[0003] A directional valve of the type mentioned in the form of an exhalation valve on a respirator mask has become known from DE 10 27 518. The directional valve consists of a valve lower part with a valve seat and a closing element held in the center by a web. To limit the lateral forces developing during deformation of the closing element, the closing element has a truncated-cone-shaped design and has disk-shaped sections offset against one another in a step-like manner. The drawback of the prior-art directional valve is that in the direction of flow through the closing element, only a part of the cross-sectional area is released, and, if the directional valve is within a breathing tube, the breathing gas is deflected through the closing element towards the tube wall, which increases the flow resistance. In the use of directional valves in closed-circuit respirators, low flow resistances are required in order to limit the breathing effort of the user of the device to a minimum.
[0004] Closed-circuit respirators supply a user of the device with breathing gas when work has to be done in an environmental atmosphere with toxic gases. Within the closed-circuit respirator the breathing gas is guided in the closed circuit, wherein exhaled carbon dioxide is removed and then consumed breathing gas is replaced. To achieve a directed breathing gas transport within the breathing closed circuit, directional valves are provided both in the inhalation tube and in the exhalation tube. A closed-circuit respirator of the type mentioned is disclosed in, for example, DE 39 30 362 C2.
SUMMARY OF THE INVENTION
[0005] The basic object of the present invention is to improve a directional valve of the type mentioned with regard to a low flow resistance.
[0006] According to the invention, a directional valve for a respirator product is provided with an inner area and an outer area, a ring-shaped valve housing in the outer area and two diaphragm-like valve disks abutting against one another at a line of separation, which valve disks have each a first section fixed at the valve housing and a movable second section running towards the line of separation. The valve housing has a central web as a valve seat running along the line of separation and support webs arranged on both sides of the central web. The valve disks are designed as resting on the central web and the support webs in the locking direction and as removable in a flap-like manner by the breathing gas stream in the passing direction.
[0007] The valve disks may advantageously consist of disk-shaped rubber or elastomer material, and preferably of silicone rubber. The valve disks may have an average thickness between 0.6 mm and 1.2 mm.
[0008] The inside diameter of the valve housing may advantageously be between 35 mm and 50 mm. The valve disks may have a Shore hardness of 20° Sha to 30° Sha.
[0009] The directional valve according to the present invention has two valve disks abutting against one another at a line of separation, which have a semicircular design, wherein the line of separation is the axis of symmetry of the valve disks. The valve disks consist of thin, flexible elastomer material and are each attached in a punctiform manner in a first section at a valve housing with a ring-shaped design. The valve disks cover the inside cross-sectional area of the valve housing. In a second section adjacent to the first section, which runs up to the line of separation, the valve disks are freely movable. As a contact surface for the valve disks, the valve housing has a central web running along the line of separation, and support webs are additionally arranged on both sides of the central web. In the locking direction of the directional valve, the valve disks lie on the central web and the support webs, and in the passing direction, they are opened in a flap-like manner by the breathing gas stream. If the directional valve is arranged in a breathing tube, the valve disks lie against the inner wall of the breathing tube in the passing direction, and the breathing gas can flow freely through the valve housing without the gas stream being deflected or obstructed in any way by the valve disks. The punctiform attachment of the valve disks in the first section additionally brings about that the valve disks are able to move in the breathing gas stream without greater restoring forces.
[0010] The valve disks may comprise thin rubber or elastomer material, and preferably of silicone rubber. The average thickness of the valve disks is between 0.6 mm and 1.2 mm; a preferred thickness is 0.8 mm. To achieve a good flow of the valve housing, its inside diameter is between 35 mm and 50 mm, the preferred diameter is 40 mm. The valve disks have a Shore hardness between 20° Sha and 30° Sha.
[0011] An exemplary embodiment of the directional valve according to the present invention is shown in the figures and explained below in greater detail. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings:
[0013] FIG. 1 is a sectional view showing a first directional valve according to the state of the art;
[0014] FIG. 2 is a perspective sectional view showing a directional valve according to the present invention;
[0015] FIG. 3 is a perspective view showing the directional valve according to FIG. 2 in the flow direction;
[0016] FIG. 4 is a perspective view showing the directional valve according to FIG. 2 in the locking direction;
[0017] FIG. 5 is a schematic view showing an arrangement for testing a respirator;
[0018] FIG. 6 is a view showing measurement curves for the directional valve according to the present invention and a directional valve according to the state of the art, for a respiratory minute volume of 50 L; and
[0019] FIG. 7 is a view showing measurement curves according to FIG. 6 for a respiratory minute volume of 100 L.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to the drawings in particular, FIG. 1 shows a longitudinal section of a first directional valve according to the state of the art. A first valve housing 2 is connected to a breathing tube 4 in the outer area 3 . The valve housing 2 has a flat contact surface 6 provided with holes 5 for a closing element 7 , which is attached to a web 8 arranged in the center. In the flow direction of the first directional valve 1 shown in FIG. 1 , the closing element 7 lifts up from the contact surface 6 and a gas flow through the holes 5 is possible. In the locking direction, the closing element 7 lies on the contact surface 6 and closes the holes 5 .
[0021] FIG. 2 illustrates a longitudinal section of a second directional valve 10 according to the present invention. A second, ring-shaped valve housing 11 is connected to the breathing tube 4 . Two semicircular valve disks 12 , 13 are attached to the second valve housing 11 in such a way that they, starting from a fixed section 14 , 15 at the second valve housing 11 , have a movable, second section 17 , 18 , running towards a common line of separation 16 . The second valve housing 11 is provided with a central web 19 running along the line of separation 16 , which serves as the valve seat for the valve disks 12 , 13 , wherein additional support webs 20 , 21 are located on both sides of the central web 19 .
[0022] FIG. 2 shows the second directional valve 10 in the flow direction, in which the valve disks 12 , 13 lift up in a flap-like manner from the webs 19 , 20 , 21 . In the locking direction the valve disks 12 , 13 lie on the webs 19 , 20 , 21 .
[0023] FIG. 3 shows a perspective view of the second directional valve corresponding to FIG. 2 in the flow direction. By contrast, FIG. 4 shows the locking direction of the second directional valve. Identical components are provided with the same reference numbers of FIG. 2 . The outer area 3 of the second valve housing 11 is used for attaching the valve disks 12 , 13 to the fixed sections 14 , 15 , while the inner area 23 of the second valve housing 11 is covered by the valve disks 12 , 13 .
[0024] FIG. 5 schematically shows an arrangement for testing a respirator, which consists of a closed-circuit respirator 30 and a reciprocating pump 31 . The closed-circuit respirator 30 comprises an inhalation tube 32 with an inhalation valve 33 , an exhalation tube 34 with an exhalation valve 35 , a regeneration cartridge 36 for the absorption of carbon dioxide, a breathing bag 38 loaded by a spring 37 and a demand oxygen system 39 with a pressurized gas source 40 . The inhalation tube 32 and the exhalation tube 34 are connected to one another at a breathing connection 41 , and the connection is made via the breathing connection 41 to a pressure space 42 of the reciprocating pump 31 . The pressure space 42 of the reciprocating pump 31 is defined by an elastomer diaphragm 43 with a piston 44 , whereby breaths are produced by means of a drive 45 , which is connected via a push rod 46 to the piston 44 .
[0025] A first pressure pickup 47 determines the differential pressure ΔP 1 via the inhalation valve 33 , and a second pressure pickup 48 determines the differential pressure ΔP 2 via the exhalation valve 35 . The pressure pickups 47 , 48 and the drive 45 are connected via data lines 49 , 50 , 51 to a control unit 52 , which controls the testing and issues measured values via a display unit 53 .
[0026] The demand oxygen system 39 , which replaces the consumed breathing gas during the normal use of the device, serves only for replacing the gas loss due to leaks during the testing.
[0027] A certain excess pressure is produced within the breathing circuit of the closed-circuit respirator 30 by the spring 37 which presses on the breathing bag 38 . During exhalation, the breathing gas flows from the breathing connection 41 via the exhalation tube 34 , the exhalation valve 35 and the regeneration cartridge 36 into the breathing bag 38 as storage volume. During inhalation, the breathing gas arrives from the breathing bag 38 and the inhalation valve 33 into the inhalation tube 32 and to the breathing connection 41 .
[0028] Measurement results with directional valves according to the state of the art according to FIG. 1 and directional valves according to the present invention according to FIG. 2 are compared in FIG. 6 . The testing was performed with a respiratory minute volume of 50 L, corresponding to 25 strokes per minute with the reciprocating pump 31 and a stroke volume VT of 2 L.
[0029] FIG. 6 shows pressure measurement curves for a complete breathing cycle each, consisting of inhalation stroke and exhalation stroke. The time course of the breath V(t) with the maximum value VT is shown on the abscissa and the measured pressure differences ΔP 1 and ΔP 2 are shown on the ordinate. The measurement curves 60 and 61 illustrate the pressure courses in a directional valve according to FIG. 1 . Curve 60 shows the pressure course ΔP 1 for the inhalation valve 33 in the inhalation phase and curve 61 shows the pressure course ΔP 2 for the exhalation valve 35 during the exhalation phase. During the inhalation phase the breathing gas is removed from the breathing bag 38 , and the breathing resistance of the inhalation valve 33 must be overcome, which causes a certain inhalation effort. In the exhalation phase according to curve 61 for ΔP 2 , a rise in pressure is shown, since, in addition to the exhalation valve 35 , the resistance of the regeneration cartridge 36 must be overcome, and the breathing bag 38 is filled against the force of the spring 37 .
[0030] Curve 62 illustrates the pressure course ΔP 1 during the inhalation phase for a directional valve according to the present invention according to FIG. 2 . A marked reduction in the inhalation effort can be seen compared to curve 60 . During the exhalation according to curve 63 and the pressure ΔP 2 , only the system-related flow resistances, caused by the regeneration cartridge 36 and the breathing bag 38 loaded by the spring 37 , have to be overcome.
[0031] FIG. 7 shows measurement results for a respiratory minute volume of approximately 100 L corresponding to 29 strokes per minute with a stroke volume of 3.5 L. The curves 64 , 65 show the pressure courses ΔP 1 and ΔP 2 for a directional valve according to FIG. 2 . During the inhalation phase with the pressure course ΔP 1 , the directional valve according to FIG. 2 , represented by the curve 66 , shows a significantly lower flow resistance than the directional valve according to FIG. 1 , with the curve 64 .
[0032] While specific embodiments of the invention have been described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
LIST OF REFERENCE NUMBERS
[0000]
1 First directional valve
2 First valve housing
3 Outer area
4 Breathing tube
5 Hole
6 Contact surface
7 Closing element
8 Web
10 Second directional valve
11 Second valve housing
12 , 13 Valve disk
14 , 15 Fixed section
16 Line of separation
17 , 18 Second section
19 Central web
20 , 21 Support web
23 Inner area
30 Closed-circuit respirator
31 Reciprocating pump
32 Inhalation tube
33 Inhalation valve
34 Exhalation tube
35 Exhalation valve
36 Regeneration cartridge
37 Spring
38 Breathing bag
39 Demand oxygen system
40 Pressurized gas source
41 Breathing connection
42 Pressure space
43 Elastomer diaphragm
44 Piston
45 Drive
46 Push rod
47 First pressure pickup
48 Second pressure pickup
49 , 50 , 51 Data lines
52 Control unit
53 Display unit
60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 Measurement curve
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A directional valve for a respirator product shall be improved with regard to a low flow resistance. To accomplish the object, two diaphragm-like valve disks ( 12, 13 ) abutting against one another at a central line of separation ( 16 ) that are attached to the valve housing ( 11 ) in a point-like manner and can be moved in a flap-like manner by the breathing gas stream are provided. A central web ( 19 ) at the valve housing ( 11 ), which runs along the line of separation ( 16 ) and support webs ( 21 ) additionally arranged on both sides, is used as a valve seat.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims priority to co-pending German Patent Application DE 10 2009 045 769.0, filed Oct. 16, 2009 which is hereby expressly incorporated by reference in its entirety as part of the present disclosure.
FIELD OF THE INVENTION
The present invention relates to the field of producing hollow bodies from plastics, in particular to a method of producing hollow plastic bodies by means of a heated forming tool. The present invention further relates to hollow plastic bodies with novel properties.
BACKGROUND OF THE INVENTION
A plurality of manufacturing processes for producing hollow plastic bodies is known from the prior art. In the simplest case, two separate halves of a hollow plastic body, such as of a fuel tank for a motor vehicle, are formed from a thermoplastic synthetic material, for example by compression molding, which are then, for example, thermally welded together in a subsequent process step. This manufacturing process is comparatively laborious because the individual steps cannot be carried out in a machine. Moreover, the stress-resistance of the produced weld is rather low.
Higher-quality hollow plastic bodies that have a high mechanical stress-resistance, e.g. in relation to a super-atmospheric internal pressure, may be produced by means of the so-called blow molding extrusion technique. For this purpose, a tube is extruded from a thermoplastic synthetic material, which is expanded by means of air blown in and fed to the cavity of a heated molding tool. Seamless hollow bodies with a more complex shape can in that case also be molded in the cavity. Seams that weaken the structure can be minimized in this way. Modern blow molding methods even permit varying wall thickness in the hollow body produced. Blow molding methods can be used, for example, for producing bottles, canisters, barrels, tanks, pipes and tubes. But hollow bodies with a more complex shape, such as highly tight fuel tanks, structural parts or engine compartment enclosures for motor vehicles, and even transport pallets can be produced by means of the blow molding technique. One draw-back of the blow molding technique is the comparatively high machine expenditure, which prohibits employing this technique for small quantities. In addition, combinations of different materials, for example with different chemical or physical properties, are not possible.
SUMMARY OF THE INVENTION
In accordance with a first aspect, it is an object of the present invention to provide a method for producing hollow plastic bodies that can be employed rationally also in the case of small quantities.
It is another object of the invention to provide a hollow plastic body with improved properties as well as a method for its production.
The present invention further relates to various advantageous developments of the method according to the invention and of the hollow plastic body according to the invention, which—so far as is technically feasible—can be combined with each other in any way.
The method according to the invention is provided for producing hollow plastic bodies and comprises the following process steps:
(1) providing a material composite consisting of:
(a) a panel or sheet-like first layer of a first thermoplastic synthetic material, (b) a panel or sheet-like second layer of a second synthetic material, (c) a panel-like, open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer,
(2) feeding the material composite to the opened cavity of a heated molding tool, and (3) closing the molding tool, wherein pressure is applied onto the material composite at least in some sections such that, in the pressurized sections, the first and/or second layer is thermoformed and the foam layer is compressed, which results in a permanent deformation, at least of the first layer and/or the second layer from their preferred plane initial configuration, and of the foam layer.
The process according to the invention permits the production of hollow plastic bodies, the interior of which is entirely or partially filled with a foam. In this case, process control can be selected such that the first or/and second layer, in the molding tool, detaches from the foam layer in such a way that the foam layer is in mechanical contact with the first or/and second layer substantially only in the compressed sections. An air or gas-filled void, which can preferably be sealed on all sides, forms in the areas without mechanical contact. The air or gas, which apart from the remaining foam layer fills the voids created, to a substantial extent stems from the cells in the compressed areas of the previously open-cell or mixed-cell foam layer. However, it is also possible that the foam layer substantially completely fills the voids created.
The formation of air or gas-filled voids can be facilitated by drawing air from the cavity when the molding tool is being closed. In particular, a negative pressure can be produced in the cavity when air is being drawn out. As an alternative or aid, air or an inert filling gas can be blown between the first layer and the foam layer or/and the second layer and the foam layer, which additionally promotes the formation of air or gas filled structures.
In an alternative embodiment of the method, which, however, is also comprised by the scope of the present application, the foam layer is omitted completely. The formation of the hollow chambers is aided by blowing in air between the first and the second layer of synthetic material and/or by drawing out air from the cavity of the molding tool during closing it or by generating a negative pressure in the cavity.
In a preferred embodiment of the method, the first layer is preferably thermally welded, in the pressurized sections, to the second layer and/or to the foam layer. Welding can, however, optionally be carried out by means of other welding techniques. In particular, welding can be carried out such that it mechanically connects the material composite at the edges at least in some areas, preferably, however, along the entire periphery, so that an interior space is produced which is completely sealed against the environment. The first layer of synthetic material is thus preferably welded to the first foam layer and/or the second layer of synthetic material in such a way that the hollow plastic body produced encloses a substantially completely sealed air/gas compartment.
It is of pivotal importance for an effective process control that the first and second synthetic material can be welded to each other, in particular by means of thermal welding. Furthermore, it has proved to be advantageous if the third synthetic material preferably can also be thermally welded to the first and/or the second synthetic material.
As described above, the first synthetic material may be a thermoplastic. In some embodiments, the second and the third synthetic material is also a thermoplastic. In this case, both the first and the second synthetic material can advantageously be selected from the group consisting of the materials ABS, GMT, LWRT, PMMA, PVC, PE, PET, PS, PP, PSEVOHPE, PPEVOHPE, PEEK. The second and/or particularly the third synthetic material can also be a duroplastic or an elastomer. However, the third synthetic material is particularly preferably a foamed synthetic material selected from the group consisting of the materials PUR, PPE, PSE, PVCE, NBR, PF. The foam should be open-cell or mixed-cell. If a thermoplastic foam is selected, then the use of a closed-cell foam can possibly also be possible and advantageous.
The method according to the invention is particularly advantageous in that the first and second synthetic material can, but need not be, chemically and/or physically different. Thus, the first and second synthetic material can have different colors, resulting in design-related advantages which may become relevant, for example, in the production of noise protection elements with a visible side and a functional side. Moreover, the panel or sheet-like first synthetic material can have different mechanical properties from the panel or sheet-like second synthetic material, for example by using different material thicknesses of one and the same synthetic material. Alternatively, either the second synthetic material can also be a fiber-reinforced synthetic material (GMT, LWRT) having a high impact resistance. In contrast, the first synthetic material can be an unfilled/unreinforced thermoplastic, such as PP, which is excellent to thermoform. Such a combination of materials can, for example, be used advantageously for producing acoustically effective engine compartment enclosures, with the reinforced side facing in the direction of the vehicle underbody, and the PP side in the direction of the engine compartment. The PP side then forms the acoustically effective structures.
A hollow plastic body according to the invention comprises a material composite comprising at least the following components:
(i) a stamp-formed, panel or sheet-like first layer of a first thermoplastic synthetic material, (ii) an optionally press-formed, panel or sheet-like second layer of a second synthetic material, (iii) an open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer, (iv) wherein, the foam layer is compressed at least in some sections in accordance with the stamped form of the first layer and/or the second layer.
In this case, the hollow plastic body is preferably configured such that the foam layer is in mechanical contact with the first or/and second layer substantially only in the compressed sections. In the areas therebetween, the hollow plastic body preferably forms air or gas-filled voids or chambers. However, it is also possible that the foam layer substantially completely fills the voids or chambers created.
Preferably, in the hollow plastic body according to, the invention, the first layer in the compressed sections is preferably thermally welded to the second layer and/or the foam layer, advantageously such that the weld connects the material composite at least in some areas at the edges. Particular advantages result if the hollow plastic body encloses a substantially completely sealed air compartment, e.g. by means of a substantially complete peripheral thermal weld. For example, it has proved to be particularly advantageous for the production process of a hollow plastic body according to the invention if the first and the second synthetic material can be thermally welded to each other. In that case, the hollow plastic body can be produced particularly simply and efficiently by means of a preferred embodiment of the method according to the invention. Even more improved product properties are obtained if, furthermore, the third synthetic material preferably can also be thermally welded to the first and/or the second synthetic material.
With regard to selecting the first, second and third synthetic material, reference is made to the above comments on the selection of materials and the chemical or physical properties in the context of the method according to the invention, which are immediately transferable to the hollow bodies according to the invention.
Other advantages and features of the method according to the invention and of the hollow body according to the invention are apparent from the dependent claims as well as from the exemplary embodiments discussed below. These are to be understood to be examples and non-limiting, and will be explained in more detail with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a material composite for carrying out the method according to the invention;
FIG. 2 shows a material composite for carrying out the method according to the invention;
FIG. 3 shows the material composite inserted in the opened cavity of the molding tool;
FIG. 4 shows the molding tool with the inserted material composite during the closing process;
FIG. 5 shows the largely closed molding tool with the inserted material composite in which hollow bodies begin to form;
FIG. 6 shows the completely closed molding tool with the inserted material composite in which hollow bodies have formed;
FIG. 7 shows a first variant of the product according to the invention, produced in accordance with the method according to the invention;
FIG. 8 shows a second variant of the product according to the invention, produced in accordance with the method according to the invention; and
FIG. 9 shows a third variant of the product according to the invention, produced in accordance with the method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the individual components of a material composite with which the method according to the invention is carried out. The material composite comprises a first layer 10 consisting of a thermoplastic material, such as PP, which is panel-shaped and has a thickness in the range of between 0.5 and 2.5 mm. A second layer 20 , which also consists of a thermoplastic synthetic material, but which is reinforced, for example, with glass fibers and has an increased thickness in the range of between one and five millimeters, is disposed on the underside.
A foam layer 30 consisting of an open-cell synthetic material, for example of PUR (generally duroplastic or elastomeric) is disposed between the first layer 10 and the second layer 20 . The thickness of this foam layer is generally between one and twenty millimeters, but may be more or less. Besides open-cell foams, the use of mixed-cell foams is also possible in principle. While FIG. 1 shows the individual layers of the material composite individually for illustrative purposes, FIG. 2 shows the material composite in the form in which it is supplied to the cavity of a molding tool 40 .
FIG. 3 shows the opened cavity of a molding tool, which forms a first mold half 40 and a second mold half 45 . The two mold halves 45 are heated and moveable relative to each other, so that the cavity formed between the form halves 40 and 45 can be closed. Such a molding tool is known from the prior art and is thus not described in greater detail. The molding tool can be heated directly by means of heating elements integrated into the form halves 40 , 45 . However, it can also be disposed on heatable tool tables of a hot-plate press, so that the mold halves 40 , 45 are heated via the tool tables, which are not shown in FIG. 3 . Common operating temperatures for the molding tools are in the range of 250° C. to about 350° C., depending on the (thermoplastic) synthetic material, preferably in the temperature interval between 250° C.-270° C. and 300° C.
FIG. 4 shows the start of the closing process of the molding tool by moving the mold halves 40 , 45 relative to each other, with the material composite inserted in the cavity of the molding tool also being shown. In this case, arrows indicate that the thickness of the foam layer 30 is less than the depth of the shapes of the structures formed in the upper mold half 40 .
FIG. 5 shows the compression of the material composite occurring when closing of the mold halves is continued, the compression being accompanied by the first layer 10 becoming detached from the underlying foam layer 30 in the area of the voids 50 of the first mold half 40 of the molding tool. In these areas, the foam layer 30 is compressed to a lesser extent than in the surrounding areas.
FIG. 6 shows the closed state of the molding tool, in which box-like structures have formed in the first layer 10 by thermal deformation of the first layer 10 . Furthermore, an irreversible deformation of the foam layer 30 has taken place in the sections pressurized by the mold halves 40 , 45 of the molding tool, which is accompanied by a thermal welding of the material composite in these areas. An air-filled volume designated 60 is located within the box-shaped structures, besides the foam layer 30 (which, locally, is compressed only slightly or not at all). In this case, the shape of the molding tool is selected such that the interior of the produced box structure is completely sealed against the environment. This is ensured by thermally welding the material composite on all sides by an uninterrupted welding seam.
The formation of the air-filled box structures in the context of the method according to the invention cited above is primarily based on the fact that, when the mold halves 40 and 45 of the molding tool are closed, air captured in the pores of the open or mixed-cell foam of the foam layer 30 escapes and leads to an inflation of the chamber structures. This inflation can be aided in process control by air being drawn out of the cavity of the molding tool when the molding halves of the molding tool are being closed. In particular, this can be carried out by generating a certain negative pressure in the molding tool, so that the first layer 10 , which has been made mobile by heating, is “sucked” into the box structures of the upper molding half 40 of the molding tool. This evacuation of the interior of the cavity is indicated by the arrows in FIG. 3 pointing out of the cavity.
Moreover, the formation of the air or gas-filled (here: box) structures can be aided additionally in the context of the manufacturing process of according to the invention, if air or (inert) gas is blown in, preferably in the area of the foam layer 30 , particularly preferably into the area captured between the foam layer 30 and the first layer 10 and/or the second layer 20 , when the material composite is being fed to the cavity of the molding tool. This can take place, for example, while feeding the panel-shaped first layer 10 and the panel-shaped foam layer 30 , by blowing in pressurized air or another inert gas between these layers.
The box structure produced when the method according to the invention is carried out in the exemplary embodiment discussed is shown once again in FIG. 7 in a first variant in which it is ensured, by means of the special process control, that a residual material thickness d of the foam layer 30 remains in the compressed sections 70 of the structure. This residual material thickness d can be specifically set by the process control and the shaping of the molding tool. In the shown first product variant, it is typically between 0.1 and 1 mm.
FIG. 8 shows a second product variant that substantially corresponds to the product variant apparent from FIG. 7 , wherein the process control was selected such that the PUR foam material of the foam layer 30 was displaced virtually completely in the compressed sections 70 , in the production of the product shown in FIG. 8 . Accordingly, this is a practically direct weld connection of the first layer 10 with the second layer 20 , which can lead to an increased strength of the material composite in the finished product.
Finally, FIG. 9 shows a third variant of the finished product which was produced by means of a molding tool, in which the lower molding half 45 is also structured such that the second layer 30 is also pressurized locally, so that opposite depressions are formed both in the first layer 10 as well as in the second layer 20 . It is particularly simple in this variant to displace virtually the entire material of the foam layer 30 from the compressed sections 70 and thus obtain a mechanically particularly highly stress-resistant weld connection of the first layer 10 with the second layer 20 .
Finally, reference is made to the fact that the use of an open-cell or mixed-cell foam layer 30 disposed between the first layer 10 and the second layer 20 has proved to be particularly advantageous for the method according to the invention. Within the context of practical tests of the method according to the invention, however, it was found that a foam layer 30 can be dispensed with entirely, given a suitable process control, in particular if, when the material composite is fed to the cavity of the molding tool, air is additionally blown between the first layer 10 and the second layer 20 and/or air is drawn out of the cavity of the molding tool, in particular setting a negative pressure in the cavity of the molding tool.
The particular advantage of the method according to the invention in all its special embodiments lies in the fact that the requirements with regard to the machine tools to be used are significantly reduced as compared with the blow-molding machines frequently used for producing hollow plastic bodies. Therefore, the method according to the invention is particularly suitable for producing small series of hollow plastic bodies which could not be produced rationally using the blow-molding technique.
In particular, the product according to the invention is advantageous in that various material combinations of the first layer 10 and the second layer 20 can be prepared, which in particular makes it possible to realize individual aesthetic designs for example by coloring the first layer 10 and the second layer 20 differently. Moreover, special requirements with regard to the physical or chemical properties of the first layer 10 and the second layer 20 can be realized. For example, there may be cases of application in which a very high mechanical stability of the second layer 20 , which forms a more ore less plane surface, is desired. As an example, reference may be made to an engine compartment enclosure for a motor vehicle as it is apparent from EP0775354B1, for example. The underside of the engine compartment enclosure at the same time forms the vehicle underside, and must therefore have an increased mechanical stress-resistance. Fiber-reinforced, thermoplastic synthetic materials such as GMT or LWRT are particularly suitable for this purpose. However, particularly good acoustic properties are obtained if the box structure directed towards the engine compartment is fabricated from a thinner material with good vibrating capabilities, such as, for example, PP.
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A hollow plastic body comprises a material composite consisting of a stamp-formed panel or sheet-like first layer of a first thermoplastic synthetic material, an optionally stamp-formed panel or sheet-like second layer of a second synthetic material, and an open-cell or mixed-cell foam layer of a third synthetic material disposed between the first and the second layer. The foam layer may be compressed at least in some sections in accordance with the stamped form of the first layer and/or the second layer. The foam layer may be in mechanical contact with the first or/and second layer substantially only in the compressed sections. Advantageous manufacturing methods for hollow plastic bodies are further disclosed.
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RELATED CASE
This is a continuation of application Ser. No. 512,204, filed July 8, 1983, now U.S. Pat. No. 4,663,710 which is a continuation-in-part of U.S. Patent Application Ser. No. 264,173, now U.S. Pat. No. 4,437,159.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cooking devices and more specifically to programmable cooking devices.
2. Description of the Prior Art
There has been for a long time a need for a device to control precisely cooking of foods in deep fat fryers precisely and easily. A number of approaches have been developed in the prior art.
U.S. Pat. No. 3,979,056 to Barnes for a multi-Product Cooking Computer discloses an electronic circuit having a timer controlled in part by a temperature probe submerged within heated oil or shortening in a deep fat fryer well. The temperature probe controls the rate of oscillation of an oscillator 22. Oscillator 22 drives a counter 24. When counter 24 counts a predetermined number of oscillations of oscillator 22, an output signal is provided indicating that cooking has been completed. In other words Barnes employs a temperature adjusted oscillator to perform a type of time-temperature cooking integration. Barnes also provides a plurality of product selected switches which connect different resistences in series with a capacitor 68 to control the period of the oscillator. However, should it become necessary to adjust the time for which a particular product selection is cooked, internal adjustments of a mechanical or electronic nature would have to be made to the circuit.
Another approach was taken in U.S. Pat. No. 4,197,581 to Watrous et al, for a control system for a method of controlling a cooking appliance. Watrous teaches the use of a combination micro-computer controller having associated circuitry for controlling a deep fat fryer. Watrous, preloads timing counters from a diode matrices. Watrous like Barnes, employs a temperature variable frequency oscillator but uses it to actuate computer counters. The variable frequency oscillator of Watrous is controlled by a cooking control probe R801 so that as the probe, which is submerged in heating oil, becomes warmer, the oscillator runs faster. There is no provision in Watrous for altering the pre-load cooking counter without rewiring a circuit board.
SUMMARY OF THE INVENTION
In accordance with the present invention a cooking appliance is provided that includes a heating source to provide heat to a cooking medium for cooking food. A temperature sensing circuit is further provided for detecting the cooking medium temperature. Control circuitry is provided that is connected to the temperature sensing circuit for cooking the food according to data stored in the control circuitry and by controlling the heating source and removing the food from the cooking medium in accordance with the data.
In an embodiment of the present invention a cooking appliance is provided that includes the heat source to provide heat to a cooking medium of cooking oil or shortening. A temperature sensing circuit is provided for detecting the temperature of the cooking oil. Control circuitry is further provided that is connected to the temperature sensing circuit for cooking the food according to data stored in the control circuitry. The control circuitry further includes input storage circuitry that allows the user to input the cooking data. The control circuitry further includes data processing circuitry to compute the cooking time and the cooking temperature in accordance with an algorithm stored in the control circuitry and with the user entered and stored cooking data. In this preferred embodiment the input storage circuitry includes a non-volatile random access memory for storing the user input cookig data. The control circuitry further includes an output display to the user that includes both a visible indicia and an audio indicia. The control circuit further includes a cooking sensitivity input that allows the user to alter the computation of the cooking temperature by the algorithm stored in the control circuitry. This control circuitry further includes a protective circuit to protect the cooking data from being accessed by unauthorized persons.
Also in accordance with the present invention a temperature sensing apparatus is provided that includes a temperature probe for measuring temperature, a reference circuit indicating a reference temperature, and a circuit that is alternately connected to the temperature probe and to the reference circuit for alternately providing first and second output signals indicative of the measured temperature and the reference temperature respectively. Further provided is data processing circuitry for receiving the output signals and computing the measured temperature from the first and second output signals.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as other features and advantages thereof, will be best understood by reference to the detailed description which follows, read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of the cooking appliance controlling circuits.
FIG. 2 is a side sectional view of the cooking appliance.
FIG. 3 is a schematic diagram of the central processing unit.
FIG. 4 is a schematic diagram of the clock.
FIG. 5 is a schematic diagram of the temperature input circuit.
FIG. 6A is a schematic diagram of the random access memory.
FIG. 6B is the schematic diagram of an address multiplexer and the read only memory.
FIG. 6C is a schematic diagram of the non-volatile memory.
FIG. 6D is a schematic diagram of the address select logic.
FIG. 7 is a schematic diagram of the product display circuitry.
FIG. 8A is a schematic diagram of the eight 7-segment light emitting diode displays.
FIG. 8B is a schematic diagram of the driving circuit for the discreet light emitting diodes.
FIG. 8C is a schematic diagram of the driving circuits for the discreet outputs.
FIG. 9 is a schematic diagram of the power supply.
FIG. 10 is a schematic diagram of the keyboard input circuitry.
FIG. 11 is a schematic diagram of the external signal connector.
FIG. 12 is a front view of the control panel.
FIG. 13 is a schematic diagram of the relay interconnection.
FIG. 14 is a schematic wiring diagram.
FIG. 15 is a flow chart for the power up and initialization routine.
FIG. 16 is a flow chart of the Magic routine that is the principle executive operational routine.
FIG. 17 is an intialization routine for the Magic executive routine.
FIGS. 18 through 39 are flow charts for the keyboard processing routines.
FIGS. 40 through 45 are flow charts for the operator display program.
FIG. 46 is a flow chart of the sound generation routine.
FIGS. 47 through 49 are flow charts for the cooking display routine which includes the display procedures executed during the cooking cycle.
FIG. 50 is a flow chart for the holding routine which includes the display procedures during the holding cycle.
FIG. 51 is a flow chart for the recovery time display procedures routine.
FIG. 52 is a flow chart for a display procedure routine for displaying the program temperature and the measured temperature.
FIG. 53 is a flow chart for the interface board disable procedure routine.
FIGS. 54 through 59 are flow charts for the analog/digital (A/O) conversion procedures routine that include the task of sampling the A/D converters, testing for a bad probe, testing for over temperature and testing for the existence of the pilot alarm.
FIG. 60 is a flow chart for a delay routine.
FIG. 61 is a flow chart for the melt cycle procedure routine.
FIG. 62 is a flow chart for the heating cycle procedure that controls the heating of the vat from 180 degrees to 20 degrees below the designated operating temperature.
FIGS. 63 through 67 are flow charts for the controlling routine which controls the rate of temperature rise and the amount of heat provided to the cooking oil.
FIGS. 68 and 69 are flow charts for the gas valve control procedures routine.
FIGS. 70 and 71 are flow charts for the procedure that computes the rate of temperature rise.
FIG. 72 is a flow chart of the procedure that sounds the alarm when a bad probe is found.
FIG. 73 is a flow chart for the routine that sounds the alarm when the cooking oil temperature exceeds a high limit of 410 degrees F.
FIG. 74 is a flow chart for a procedure that displays an indication that the temperature of the cooking oil is 15 degrees above or below the set temperature point and if the temperature is within 15 degrees range of the set point dashes are displayed on the seven segment LED displays.
FIG. 75 is a flow chart for a procedure that sounds the alarm when the pilot is not fired.
FIG. 76 is a flow chart for a procedure that is activated when there is an input code access error.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a controller for an automatic cooking appliance. The central processing unit (CPU) 25 is the intelligence of the controller. CPU 25 is connected to clock 27 by lines 26 which provide the timing signals for the internal operations of the CPU 25. CPU 25 is also connected to the temperature input 29 by a line 28. Temperature input 29 provides the temperature of the cooking medium to the CPU 25. CPU 25 is also connected to the keyboard input 20 via lines 23 and 24. Lines 23 represent control and discreet lines that connect the CPU 25 to the different peripheral devices. Lines 24 are address and data lines for the transfer of address and data information to and from the CPU 25. The keyboard input 20 provides the user input to the CPU 25. CPU 25 is also connected to the display 21 to display an output to the user. CPU 25 is further connected to memory 22. Memory 22 stores permanent program data in addition with user entered cooking data and provides temporary storage. CPU 25 is further connected to control output circuitry 31 via lines 30. The control output circuitry 31 provides the external control functions to control the cooking of the food in accordance with the data stored in memory 22.
FIG. 2 illustrates the one embodiment of the present invention. Vat 16 contains a cooking oil or cooking shortening provided to cook food that is placed inside basket 18. This deep fat frying mechanism is used to fry foods. Controller 10 controls not only the cooking temperature of the oil in vat 16 but also the time of the food that is cooked in basket 18 by raising and lowering basket 18 via motor and gear mechanism 19. Controller 10 is further connected to a temperature sensing device 14. Device 12A is a heating element that in the preferred embodiment of the invention is a gas fired element to provide heat to the oil in vat 16. Device 12B is a thermostat control for the heating element 12A.
The CPU 25 of FIG. 1 is illustrated in FIG. 3. FIG. 3 illustrates the microprocessor semiconductor device 41 connected to a watchdog timer circuit consisting of flip-flops 44 and 45. In the preferred embodiment the microprocessor is an RCA 1802 CMOS microprocessor. The CMOS microprocessor is provided to reduce the heat dissipated by the controlling device. Microprocessor 41 is connected to a network of resistors for the data input on the lines as indicated. A reset signal provided by the user is connected to an AND gate 40 that provides the reset or clear function to the microprocessor 41. The R2 and C2 network insure that power has been applied for a specific time before AND gate 40 resets CPU 41. Microprocessor 41 provides data via the data lines DB0 to DB7 and addresses via address lines MA0 to MA7. It should be noted that the address lines are multiplexed in the 1802 (i.e. line MA0 to MA7 contain a 16 bit address). Resistor networks 42 and 43 are provided as pull-up resistors for the data and address lines. Flag F1 through F4 are inputs from the keyboard. N0 to N2 are programmed inputs input/output (I/O) lines. MRD- and MWR- provide the memory read memory and memory write signals, respectively. INT- is the timer interrupt. DMA0- is the input from the temperature sensing circuitry. Q is provided by the microprocessor 41 to the temperature sensor to initiate the temperature input sequence. Q is also used by the watchdog timer for initialization. SC0 through SC1 (synchronous codes) are provided to peripheral devices to indicate the state of microprocessor 41. The watchdog timer circuit consisting of flip-flops 44 and 45 is a two flip-flop timing circuit provided to reset the microprocessor 41 via AND gate 40 if the Q signal is not received within a specified time. This specific time is provided by the time constant of C11. Many of the devices used in this embodiment are from the RCA CMOS microprocessor family. Specification information of the CDP 1802, CDP 1866 and CDP 1875 is incorporated by reference.
FIG. 4 illustrates in schematic form the clock circuitry for the controller. A crystal 50 is connected to a capacitor resistor network including capacitor C13 and C14 and resistor R5 to provide an output frequency to a frequency dividing circuit 51. In the preferred embodiment, the crystal 50 provides a frequency of approximately 2.5 MHZ and device 51 is a 14-bit binary counter (4060). The frequency signal from the crystal 50 is output on the line CLK provided to the microprocessor 41 of FIG. 3. The output of frequency of crystal 50 is divided down by the counter 51 to provide a slower pulse to the flip-flop 52 to furnish a timer interrupt. The interrupt is acknowledged from the microprocessor 41 via signals SC0 and SC1 input into AND gate 53. The output of flip-flop 52 is the INT- or timer interrupt provided to microprocessor 41 as an indication of the passage of a timed period.
The temperature sensing circuit is illustrated in FIG. 5 and consists of a multiplexing semiconductor device (MUX) 62 connected to several resistance temperature devices not shown. In the preferred embodiment, the resistive temperature device is fabricated with platinum film. In this preferred embodiment applied to a two vat deep fat fryer, two of the temperature sensing devices are connected to the pilot light for a left vat (PLTL) and a pilot light for a right vat (PLTR) in the two cooking vat configuration where the vats are heated by gas and thus requiring pilot flames. In an embodiment including an igntor sub-system, this sub-system will provide a signal indicating the condition of the pilot flame. This signal is input into MUX 62. Further provided are PRBE L and PRBE R which are the temperatures of the cooking oil in the respective left and right vats. MUX 62 is further connected to a high reference resistor R21 and a low reference resistor R20 which represent the maximum and minimum temperatures measured by the temperature probes on lines PLTL, PLTR, PRBE L and PRBE R. R21 is set for 440 degrees Fahrenheit and R20 is set for 32 degrees Fahrenheit. A constant current source 63 provides a constant current to the multiplexer 62 which then connects this constant current to either the pilot probes via lines PLTL or PLTR, the vat probes via lines PRBE L or PRBE R or the reference resistors R20 or R21 in accordance with the MUX select lines P0, P1 and P2 from the CPU 41 and the output buffer in FIG. 8C. These lines P0 through P2 determine which of the temperature probes or reference lines are connected to the constant current source 63. The output voltage is connected to a voltage to frequency converter 61. Upon receiving the voltage from the MUX 62, the voltage to frequency converter converts the resulting voltage to a corresponding frequency which then is input as a clock signal into the flip-flop 60. The output of flip-flop 60 is connected to DMA0- and provided to the microprocessor 41 DMA (direct memory access) input. In the preferred embodiment, using the RCA 1802, the DMA0- input frequency count is accumulated in register 0 of the RCA 1802 to indicate the temperature of whichever probe was selected at the MUX 62. The count is initialized by an interrupt (INT-) from flip-flop 52 and stopped by the next interrupt which generates the signal Q input to flip-flop 60. An algorithm contained in microprocessor 41 computes a comparison between the probe count and the high and low reference counts to determine the exact temperature of the pilot lights or the cooking oil in the left and right vats. The algorithm computes the measured temperature by computing the frequency count difference of R21 and R20 and multiplying by 372 to compute the slope constant which is the frequency count per degree conversion factor. The probe temperature is then computed by multiplying the difference between the temperature probe count and the low reference count by the above conversion factor and then adding 32 which represents the offset. In this manner, the temperatures may be measured without extensive analog to digital conversions and other expensive peripheral devices. Using this arrangement, the temperature is input as a frequency directly into the microprocessor 41 register where it can be easily accessed by the algorithm being executed in the microprocessor 41.
FIG. 6A is a portion of the memory for the controller 10. Devices 67 and 68 are random access memory semiconductor devices that are connected to the multiplexed address lines MA0 through MA7 and the data bus lines DB0 through DB7 respectively. FIG. 6B illustrates the ROM 70 that is likewise connected to the multiplexed address lines MA0 through MA7 and the data lines DB0 through DB7. Semiconductor device 69 of FIG. 6B is the demultiplexer for the multiplex address from the RCA 1802 microprocessor 41 of FIG. 3. The TPA line is used to perform the demultiplexing operation. FIG. 6C illustrates a nonvilatile RAM which is likewise connected to the multiplexed address lines MA0 through MA7 and the data lines DB0 through DB7. FIG. 6D illustrates a selection logic semiconductor device that uses multiplex address bits 6 and 7 and the microprocessor 41 timing signal TPA together with the memory read MRD- and memory write MWR- lines to select the RAM 67 and 68, ROM 70, or nonvolatile RAM 71 semiconductor devices via signals CS0- through CS3-. In the preferred embodiment this selection logic is provided by the RCA devices CDP 1866.
FIG. 7 illustrates the discrete light emitting diode (LED) display circuitry consisting of a BCD to decimal converter 80 connected to the input semiconductor device 81 which is further connected to a resistor network 82 and the LED matrix 83. The LED matrix 83, which displays which product is being cooked, is activated by line SEL3 which is decoded from the CPU 41 outputs N1 and N2 and the data latch signal TPB. The terminals 84 mark A through F are connected to the keyboard (FIG. 10) to provide keyboard scan signals.
FIG. 8A illustrates the schematic of the seven segment light emitting diode (LED) display output. The seven segment LED displays are connected to a LED driver 90 which is connected to the data lines DB0 through DB7 from CPU 41 and select line SEL1 from the BCD to decimal converter 80 (FIG. 7). The seven segment LED displays provides alphanumeric information to the user. The UNREG line in the preferred embodiment driver 91 is a 75468 device. In the configuration pin 8 of driver is from the power supply (FIG. 9) and provides the signal to the base of transistor 96 which provides unregulated power to an interface board containing the relays previously discussed. FIG. 8B illustrates the driver 91 that is connected to an AND gate 92. Driver 91 provides the output signals (see FIG. 11) to the relays which control the gas regulator and the motor 19 of FIG. 2. Driver 91 and AND gate 92 receive the programmed input/output signals P3 through P7 from the microprocessor. FIG. 8C illustrates the output buffer 93 that provides the program 10 signals from the data signals DB0 through DB7 controlled by the select line SEL2 and the memory read signal MR0- from BCD to decimal converter 80 (FIG. 7).
FIG. 9 is the schematic diagram of the power supply for the controller and consists of switching regulator 95 connected to a full wave rectifier circuit containing diodes C13 through C16. Note that the unregulated signal from the full wave bridge rectifier is provided to the driver 91 in FIG. 8B as previously discussed. Switching regulator 95 further includes an operational amplifier that provides the RESET signal when the input voltage of the four-way rectifier falls below a certain voltage level. TP2 and TP1 are test points provided on the circuit. The output V+ is regulated through Q1 and filtered through inductor L1 and capacitor C6. The full wave bridge rectifier is connected to both chassis ground 97 and analog ground 98. In the preferred embodiment the switching regulator 95 is a Fairchild 78540. For this regulator the resistor network R15, R16, R17, R22 and R23 are configured to provide an accurate input voltage of 1.3 volts.
FIG. 10 illustrates the connection to the user keyboard 99. As previously dicussed, lines A, B, C, D, E, F, G, and H provide scan inputs to keyboard 99. The outputs of keyboard 99 are flag lines F1, F2, F3, F4 which are connected to the pull up resistor network RN3. When the user depresses a key of the keyboard 99, the connecting flag line is grounded. When read by the CPU 41, the low flag line indicates that the key being scanned was depressed.
FIG. 11 illustrates the external signal connections to the fryer appliance.
FIG. 12 is a front view of the control panel that provides both display and user inputs to the system. Display 101 contains four of the seven segment light emitting diodes. Display 102 contains the other remaining four seven segment light emitting diode displays. The storage switch 103 is provided to indicate to the system that the program contained in the computer is to be locked in. Switches 104 and 105 are power supply switches for the left and right vats. Switches 106 and 107 are the left, right and ten digit keyboard input switches used for entering the computer and accessing programming functions. Switch 108 is a program step verification switch. Table I contains the user input sequence for using the switches of FIG. 12.
FIG. 13 illustrates the schematic for an interface board that contains several relays controlled by the CPU 41 through the connection illustrated in FIG. 11. FIG. 14 is a schematic diagram for the general power wiring of the cooking device.
FIGS. 15 through 75 are flow charts for the system software that is contained in Appendix A. FIG. 15 is a flow chart for the power up and initialization routine. FIG. 16 is a flow chart of the Magic routine that is the principle executive operational routine. FIG. 17 is an initialization routine for the Magic executive routine. FIGS. 18 through 39 are flow charts for the keyboard processing routines. FIGS. 40 through 45 are flow charts for the operator display program. FIG. 46 is a flow chart of the sound generation routine. FIGS. 47 through 49 are flow charts for the cooking display routine which includes the display procedures executed during the cooking cycle. FIG. 50 is a flow chart for the holding routine which includes the display procedures during the holding cycle. FIG. 51 is a flow chart for the recovery time display procedures routine. FIG. 52 is a flow chart for a display procedure routine for displaying the program temperature and the measured temperature. FIG. 53 is a flow chart for the interface board disable procedure routine. FIGS. 54 through 59 are flow charts for the analog/digital (A/O) conversion procedures routine that include the task of sampling the A/D converters, testing for a bad probe, testing for over temperature and testing for the existence of the pilot alarm. FIG. 60 is a flow chart for a delay routine.
FIG. 61 is a flow chart for the melt cycle procedure routine. FIG. 62 is a flow chart for the heating cycle procedure that controls the heating of the vat from 180 degrees to 20 degrees below the designated operating temperature. FIGS. 63 through 67 are flow charts for the controlling routine which controls the rate of temperature rise and the amount of heat provided to the cooking oil. FIGS. 68 and 69 are flow charts for the gas valve control procedures routine. FIGS. 70 and 71 are flow charts for the procedure that computes the rate of temperature rise. FIG. 72 is a flow chart of the procedure that sounds the alarm when a bad probe is found. FIG. 72 is a flow chart for the routine that sounds the alarm when the cooking oil temperature exceeds a high limit of 410 degrees F. FIG. 74 is a flow chart for a procedure that displays an indication that the temperature of the cooking oil is 15 degrees above or below the set temperature point and if the temperature is within 15 degrees range of the set point dashes are displayed on the seven segment LED displays. FIG. 75 is a flow chart for a procedure that sounds the alarm when the pilot is not fired. Display 76 is a flow chart for a procedure that is activated when there is an input code access error.
While there has been described what are at present considered to be the preferred embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is therefore intended to cover all such changes and modifications as fall within the spirit and scope of the invention.
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A cooking appliance includes a heating source to provide heat to a cooking medium for cooking food, temperature sensing circuitry for detecting the cooking medium temperature and control circuitry connected to the temperature sensing circuitry for cooking the food according to data stored in the control circuitry by controlling the heating source and removing the food from the cooking medium in accordance with the data. A temperature sensing apparatus is also disclosed that includes a temperature probe for measuring temperature and a reference circuit indicating a referenced temperature. Circuitry is alternately connected to the temperature probe and the reference circuit for alternately providing a first and second output signal indicative of the measured temperature and the referenced temperature respectively. Data processing circuitry is also provided that receives the output signals and computes the measured temperature from the first and second output signals.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the drive with continuous movement in synchronism in the same direction of several parallel, at least pulling cables of a transportation installation comprising in operation at least one vehicle connected in line to the said at least pulling cables.
2. Description of the Prior Art
It is already known that one of the problems encountered in the construction of a transportation installation having several aerial supporting/pulling cables comprising at least one vehicle connected to all these supporting/pulling or pulling cables, resides in the necessity of driving the cables in perfect synchronism.
One solution has been proposed in French Patent No. 2 430 901 which recommends perfectly identical loops of cable, a connection of each vehicle to the cables by two pairs of grippers in order to form a rigid quadrilateral imposing the synchronous drive of the cables and a mechanical, hydraulic or electrical differential device in the vicinity of the drive motors. However, this solution was not satisfactory since it required absolutely identical loops of cable, which is never the case in practice, on account of the constraints of the trajectories which it is not always possible to respect.
European Patent No. 93.680 also teaches that it is necessary to provide two absolutely identical loops of cable, to form a rigid quadrilateral for the connection of the vehicles to the cables and to drive the cables by two strictly identical d.c. motors supplied from the same electrical supply source providing constant power by virtue of an electrical differential device. French Patent No. 2 552 716 recommends how one can construct such an electrical differential by incorporating in series resistances of fixed value in the induced circuits of the two motors, supplied in parallel from the same d.c. source. Here too, it has been found that it is not possible in practice to produce two identical loops of cable. Furthermore, the electrical differential produced by the resistances has proved to be the subject of resonance phenomena and one drawback thereof is that it is not possible to control the electrical supply of each motor. It has thus been found in practice that the cabins suspended from the cables are sometimes subject to swinging movements of great amplitude in a transverse plane with respect to the cables, which is detrimental to the comfort and safety of the passengers. Moreover, tests carried out with the differential device according to French Patent No. 2 552 726 on installations having a winding course have shown that such a device is absolutely inadequate for ensuring a synchronous drive of the two cables.
SUMMARY OF THE INVENTION
The invention thus intends to remedy the above-mentioned drawbacks of known installations and its object is to ensure the synchronous drive of several at least pulling cables of a transportation installation comprising cables and this is when the loops of cable are different, for example when the course of the installation is winding or distorted. Another object of the invention is to completely eliminate the phenomena of resonance or parasite phenomena between the means for driving the cables. Another object of the invention is to facilitate the checking and control of the drive of one loop of cable independently of the others.
To do this, the invention proposes a drive device for the continuous movement in synchronism in the same direction of several parallel, at least pulling cables of a transportation installation comprising in operation at least one vehicle connected in line to the said at least pulling cables, characterised in that it comprises separate means for driving each cable independently of the others, separate power sources supplying each drive means independently of the others, means for controlling the drive speed of at least one drive means of a cable depending on the different drive forces of the different drive means, so that these different drive forces of the cables correspond to equal travelling speeds of the cables.
The invention also proposes a drive device for continuous movement in synchronism in the same direction of two parallel, supporting/pulling, endless aerial cables of a transportation installation with aerial cables, comprising in operation at least one vehicle connected in line--in particular a series of vehicles such as cabins regularly spaced and distributed along the line--to the said cables, characterised in that it comprises two independent, separate drive means, one for each cable, two separate power sources supplying each drive means independently of the other, means for the detection of a variation in the drive force of at least one cable with respect to the initial force for which the cables move at the same speed, which is their nominal speed and means emitting at least one signal S for the correction of the drive speed of at least one of the two cables, this signal S being proportional in absolute value to the variation detected in the drive force of at least one cable and correcting the speed in order to return the force to its initial value.
Preferably, the detection means are able to detect the variation in the force of each of the cables, and for example detect a variation D in the difference ΔE between the drive forces of the cables with respect to the initial difference ΔEo between these forces for which the speeds of the cables are equal and the transmitting means emit a signal S for the correction of the speed, proportional in absolute value to this variation D, the correction taking place with the aim of cancelling-out the variation D.
The invention also relates to a method for the automatic regulation of the drive with continuous movement in synchronism in the same direction of several parallel, at least pulling cables of a transportation installation comprising in operation at least one vehicle connected in line to the said at least pulling cables, characterised in that since the said cables are driven to move independently of each other by drive devices and power sources belonging to each cable, the force necessary for the drive of each of the cables is measured permanently and the drive speed of at least one of the cables is controlled depending on the forces measured, so that the different forces necessary for the drive of the different cables correspond to equal speeds of movement of the cables.
The invention also relates to a method for the automatic regulation of the drive with continuous movement in synchronism in the same direction of two supporting/pulling, parallel, endless aerial cables of a transportation installation with aerial cables comprising in operation, at least one vehicle connected in line--in particular a series of vehicles regularly spaced and distributed along the line--to the said cables, characterised in that since each cable is driven by a drive device and a power source belonging to this cable and which are separate and independent from the drive device and power source belonging to the other cable, the force necessary for the drive of each cable is measured permanently, the difference ΔE between these forces is established and this measured difference ΔE is compared with an initial value ΔEo for which the speeds of the cables are equal and the drive speed of at least one of the two cables is corrected as soon as the measured difference ΔE is different from the initial difference ΔEo, in order to reestablish equality between these differences ΔE and ΔEo.
The invention thus makes it possible to obtain absolutely identical cable speeds and this is even when the cable loops are different. In addition, since the power supplies between the various drive means are separated and these drive means belong to each cable, one completely eliminates the phenomena of resonance or the parasite phenomena between these various drive means. In addition, with a device according to the invention, it is possible to control the drive of each cable independently of the others.
Further features and advantages of the invention will become apparent on reading the ensuing description referring to the accompanying drawing which is an electrical diagram of a drive device according to a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagram of a drive device according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although applicable to all types of transportation installations with cables, since they comprise several parallel, at least pulling cables and in operation at least one vehicle, each vehicle being connected in line to these said at least pulling cables, the invention is more particularly intended for the drive of a transportation installation comprising two supporting/pulling, parallel, endless aerial cables. The drive device illustrated in the drawing thus makes it possible to drive such cables with continuous movement in synchronism in the same direction.
The vehicles are connected, if necessary in a releasable manner, to all the at least pulling cables and they produce a mechanical connection between these cables. Consequently, the cables move at the same speed and the pulling force for the vehicles is equally distributed between the two cables. In this case, the difference ΔE between the drive forces of the cables is the same as the initial difference ΔEo between these forces, when the cables move at the same speed, but without load, without a vehicle connected to these cables. On the other hand, when one of the cables is driven at a higher speed than the others, it withstands a greater part of the pulling force of the vehicles. In this case, the difference ΔE between the drive forces of the various cables is no longer the same as the initial difference ΔEo of the drive forces of the cables moving in synchronism, without a vehicle.
Starting from this finding, the invention thus consists of measuring the drive force of the cables and modifying the drive speed of one cable, when the difference between the drive forces varies. In particular, it is possible to reduce the drive speed of one cable which withstands too great a part of the drive force and/or increase the drive speed of a cable which withstands too small a part of the drive force.
The drive device illustrated in the drawing comprises two independent, separate drive means 1a, 1b for the cables, one for each cable, two separate power sources 2a, 2b, supplying each drive means 1a, 1b respectively independently of the other, means 3 for detecting a variation in the drive forces of the cables with respect to the initial forces for which the cables move at the same speed, which is their nominal speed and means 4 emitting at least one signal S for correcting the drive speed of at least one of the two cables, this signal S being proportional in absolute value to the variation detected in the drive forces of the cables and correcting the speed with the aim of returning the drive forces to their initial values.
Each drive means 1 is constituted by a d.c. motor rotating a drive pulley 5a, 5b of one cable. Each power source 2 is constituted by an independent electrical d.c. supply--in particular comprising bridges of thyristors.
It is known that in a d.c. motor, the current I circulating in the induced circuit is proportional to the torque produced by the motor, i.e. to the drive force of the cable passing through the drive pulley set in rotation by the d.c. motor. Likewise, it is also known that the supply voltage of the induced circuit is proportional to the speed of rotation of this motor, i.e. to that of the drive pulley which is connected thereto and thus to the speed of movement of the cable passing through the drive pulley.
The transmitting means 4 are thus preferably means for transmitting at least one signal S for correcting the induced supply voltage U of at least one of the motors, this signal S being proportional in absolute value to the difference D between the measured difference ΔI between the armature currents of the two motors and the initial difference ΔIo between these currents, for which the speeds of the cables are equal, the correction of voltage being effected with the aim of cancelling-out the difference D.
If the difference ΔI=I a -I b increases, the correction signal S emitted by the transmitting means 4 is such that the difference ΔU=U a -U b between the induced supply voltages of the motors decreases, so that the difference ΔV=V a -V b between the speeds of the cables decreases. In fact, if ΔI increases, this means that the difference ΔE between the drive forces also increases. On account of the mechanical connection produced by the vehicles between the cables, this increase in the difference ΔE between the forces is necessarily due to an increase in the difference ΔV between the speeds.
Naturally, if vice versa ΔI decreases, the signal S is such that the difference ΔU increases so that the difference ΔV between the speeds of the cables increases.
According to the invention, the drive device comprises means 6a, 6b for measuring the drive speed V a , V b of the cables and means 7 for the initial regulation of the signal S emitted by the transmitting means 4, these regulating means 7 making it possible to calibrate the transmitting means 4 depending on the initial value ΔEo between the drive forces--in particular as a function of the initial value ΔIo between the armature currents.
Preferably, the means 3, 4 for controlling the speed--in particular the supply voltage--act on the drive speed of all the cables except one, the cable whereof the speed--in particular the supply voltage--is not controlled, acting as a reference and being driven at the nominal speed. For example, in the case of two cables, only one of the drive motors 1b is controlled as regards voltage by the signal S emitted by the transmitting means 4. However, the signal S is emitted as a function of the currents I a , I b circulating in the two induced circuits of the two motors 1a, 1b.
Preferably, the means 4 for emitting at least one correction signal S comprise means 8 for regulating the reaction speed with which they emit a signal S after detecting a variation D.
Similarly, the means 4 for emitting at least one correction signal S comprise means 9 for regulating the amplification gain of the absolute value of the signal S as a function of the variation D. These regulating means 8, 9 make it possible to adapt the response time and the amplification gain of the transmitting means 4 as a function of the external characteristics of the transportation installation, in order to achieve a convergent automatic regulation.
The two d.c. motors 1a, 1b preferably have a separate excitation 10a, 10b. The two motors 1a, 1b are preferably identical. The excitations 10a, 10b are preferably adjustable. The electrical supplies 2a, 2b of the motors 1a, 1b are conventionally constituted by bridges of thyristors. In such bridges of thyristors, it is known that it is possible to accede directly to the current I a I b circulating in the induced circuits. In this case, the detection means are thus constituted by simple connectors 3a, 3b connected to the bridges of thyristors 2a, 2b in order to supply to the transmitting means 4 the values of the currents I a , I b circulating in the induced circuits of the two motors 1a, 1b. The transmitting means 4 are electronic means for producing the difference ΔI=I a -I b between the currents supplied by the connection means 3a, 3b and for constituting a signal S proportional to the difference ΔI which they have produced. The transmitting means 4 are thus essentially constituted by a subtractor circuit followed by an amplifier circuit. The signal S emitted by the transmitting means 4 is supplied to one 2b of the bridges of thyristors through the intermediary of a switch 11. This signal S is connected to the bridge of thyristors 2b in order to modify the output voltage U b thereof and thus the drive speed V b of the motor 1b and of the corresponding cable.
Moreover, the voltage of the bridges of thyristors 2a, 2b are controlled by manual regulating means 12a, 12b, which allow the user to vary the speed of one and/or the other of the motors 1a, 1b.
Furthermore, the means 6a, 6b for measuring the speed V a , V b of the motors 1a, 1b are constituted for example by dynamotachymetric means which respectively supply the actual speed signals V a , V b to a speed comparator 13. This speed comparator is also able to control the bridges of thyristors 2a, 2b, as regards voltage through the intermediary of switches 14a, 14b.
A man skilled in the art knows how to produce the various functions mentioned above by suitable electronic circuits. The various circuits making it possible to produce the means mentioned above will therefore not be described in more detail.
The drive device described above operates in the following manner:
At the time of starting-up the installation or before the vehicles are put in position and connected to the cables, the switches 11, 14a and 14b are opened so that the transmitting means 4 and the speed comparator are inactive and the motors 1a, 1b are started-up thus displaying in the regulating means 12a, 12b the desired speed which is the nominal speed of the installation. Naturally, the same speed is displayed for the regulating means 12a of one cable and for the regulating means 12b of the other cable. The switches 14a and 14b are then closed, which has the effect of bringing the speed comparator 13 into operation. If the two speeds V a and V b are equal and correspond to the nominal speed, the comparator 13 does not alter the supply voltage of the bridges of thyristors 2a, 2b. On the other hand, if one or other of the speeds V a or V b is different from the desired nominal speed, the comparator 13 will emit a corresponding signal altering the supply voltage of the corresponding bridge of thyristors 2a, 2b in order to adjust the drive speed to the desired value. The speed comparator 13 is thus also a speed corrector. Such a circuit correcting the speed of a d.c. motor depending on its actual speed measured is already prior art.
When this last operation has been carried out, one is thus certain that, without a load, the two cables move at the same speed. One then opens the switches 14a, 14b in order to disconnect the comparator 13. The switch 11 is then closed in order to supply the correction signal S to the bridge of thyristors 2b. In this situation, this signal S should be zero and should not have any effect on the bridge of thyristors 2b, since the speeds V a , V b are equal and correspond to the nominal speed. Consequently, if this is not the case and if one ascertains a variation in the speed V b by virtue of the means for displaying the speed connected to the comparator 13, one acts on the means 7 for the initial regulation of the signal S in order to calibrate it to the value 0. These regulating means 7 may be constituted for example by means modifying the value of the current I b supplied to the transmitting means 4 by the detection means 3b. The regulating means 7 thus have the effect of equalizing the two currents supplied to the transmitting means 4. The calibration of these transmitting means 4 by the means 7 for regulating the initial value of the signal S may be carried out automatically by virtue of the comparator circuit 13, if means for emitting a correction signal to the regulating means 7 are provided in this comparator circuit. Calibration may also be carried out manually by acting directly on the regulating means 7 as a function of the value read on the means 15 for displaying the speed.
Such a calibration is of prime importance, since the currents I a and I b of the induced circuit of the motors are not necessarily the same when the cables move at the same speed without a load. In fact, the loops of cables are not necessarily identical.
When the calibration has been effected, the transmitting means 4 supply a zero signal S to the bridge of thyristors 2b and the speeds of movement of the two cables are the same and equal to the nominal speed displayed on the regulating means 12a, 12b. One can then connect the vehicles to the cables, either directly in the case of an installation comprising vehicles connected in a releasable manner, or by stopping the installation in the opposite case. When the vehicles are connected in line to the cables, it may happen that disturbances appear in the drive of the cables. These disturbances will be automatically detected by a variation of the induced currents I a , I b and will be compensated for by the signal S supplied to the bridge of thyristors 2b and which will have the effect of altering the supply voltage U b of the motor 1b, i.e. its drive speed V b in order to reabsorb the disturbance. For example, if the cable associated with the motor 1a goes into the lead, the motor 1a will withstand a greater torque and the current I a will consequently increase. The difference ΔI=I a -I b will increase in proportion and thus the signal S and in a positive manner. Consequently, the supply voltage U b will increase, which will have the effect of increasing the speed V b until the cable connected to the motor 1b catches up the cable connected to the motor 1a. The other cases of the drawing can obviously be deduced from that described above.
By a method for the automatic regulation of the drive with continuous movement in synchronism in the same direction of several parallel, at least pulling cables of a transportation installation according to the invention, the difference ΔI of the currents of the two motors 1a, 1b is measured and produced, this measured difference ΔI is compared with an initial difference Io for which it has previously been determined that the speeds of the corresponding cables are the same and the supply voltage of at least one of the motors 1a, 1b is controlled in order that the measured difference ΔI remains permanently equal to the initial difference Io.
In order to determine the initial difference Eo between the forces--in particular represented by the initial difference Io between the currents--the cables are driven at the same speed without any vehicle connected to the cables, the speeds of the cables are measured and the speed of at least one cable is corrected in order that all the cables move in synchronism at a substantially constant speed equal to the nominal speed of the installation and the forces--in particular the currents--necessary for driving the cables in these conditions are measured. The calibration of the transmitting means 4 is then corrected by the regulating means 7 so that the correction signal S emitted by these transmitting means 4 is zero in these conditions.
Preferably, in one method according to the invention, the speed--in particular the supply voltage--of all the cables except one is controlled, the cable whose speed--in particular the supply voltage--is not controlled acting as a reference and being driven at the nominal drive speed of the vehicles in line. This master/slave operation is not obligatory and one can imagine that the transmitting means 4 supply two signals S a , S b to the two bridges of thyristors 2a, 2b in order to control the supply voltage thereof simultaneously and in opposite directions.
The invention may be the subject of numerous variations with reference to the preferred embodiment described above, these variations being obvious to a man skilled in the art.
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A technique for driving with continuous synchronized movement a plurality of parallel pulling cables of a transportation installation in a direction parallel to the cables comprising at least one vehicle connected in line to the cables. Each cable is driven by a separate independent drive device powered by a dedicated power source. Drive forces in each drive device are monitored and used to control the drive device speed of at least one drive device so as to maintain equal cable speeds.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for the continuous production of tubing, rods and the like from crystalline quartz or other glass like materials. More particularly, this invention relates to a crucible for use in the production of elongated quartz members from a silica melt.
Various elongated members have been formed continuously by melting of quartz crystal or sand in an electrically heated furnace whereby the desired shape is drawn from the furnace through a suitable orifice or die in the bottom of the furnace as the raw material is melted. One apparatus for continuous production of fused quartz tubing, for example, is a tungsten-lined molybdenum crucible supported vertically and having a suitable orifice or die in the bottom to draw cane, rods, or tubing. The crucible is surrounded by an arrangement of tungsten heating elements or rods which heat the crucible. The crucible, together with its heating unit, is encased in a refractory chamber supported by a water-cooled metal jacket. The crucible is heated in a reducing atmosphere of nitrogen and hydrogen. Because tungsten is transported into the melt, it is important to maintain a relatively low temperature of about 2000° C.
An alternative apparatus provides clear fused quartz tubing by feeding natural quartz crystal into a refractory metal crucible heated by electrical resistance under a unique gas atmosphere to reduce the bubble content. The bubbles formed by gas entrapment between crystals and the molten viscous mass of fused quartz do not readily escape from the molten glass and, hence, remain as bubbles or ridges in the product drawn from the fused quartz melt. By substituting a melting atmosphere gas which readily diffuses through the molten material (such as pure helium, pure hydrogen or mixtures of these gases) it was possible to reduce the gas pressure in the bubbles and thereby reduce the bubble size. This process uses a mixture of 80% helium and 20% hydrogen by volume.
In a further alternative method, a product is obtained by continuously feeding a raw material of essentially pure silicon dioxide in particulate form into the top section of an induction-heated crucible, fusing the raw material continuously in an upper-induction heat zone of the crucible in an atmosphere of hydrogen and helium while maintaining a fusion temperature not below approximately 2050° C. The fused material in the lower zone of the crucible is heated by separate induction heating means to produce independent regulation of the temperature in the fused material. The fused material is continuously drawn from the lower zone of the crucible through forming means in the presence of an atmosphere of hydrogen containing a non-oxidizing carrier gas.
Unfortunately, most of the refractory metals and non-metal materials used in the crucibles of the above-described apparatus react with silica at high temperatures. At these temperatures, oxides of the refractory materials dissolve and diffuse into the silica and contaminate the glass. Such refractory material contamination causes discoloration and occlusions in the silica glass fused in crucibles made of such refractory materials. For example, refractory materials used in traditional crucibles leave at least from 12-300 ppb of the refractory materials in the silica melt. Accordingly, there is a need in the art to reduce contamination of fused glass occurring from the refractory materials. This need has increased recently as semiconductor and fiber optics manufacturing processes, a primary use for the glass products obtained from the subject production process, have required higher levels of purity.
Furthermore, the amount of refractory metal in the silica glass melt is believed to be proportional to the fusion temperature. Therefore, unless a very strict control over the furnace operating temperature is exercised, levels of refractory metal contamination can easily become unacceptable. Of course, such strict temperature operational limits imposed on the furnace operation are problematic. In fact, strict temperature limits can detract from a typical need for the higher fusion temperatures which are used to achieve better visual characteristics in the resultant fused quartz product.
BRIEF SUMMARY OF THE INVENTION
In an exemplary embodiment- of the invention, a crucible for melting of silica and subsequent drawing into a desired shape is comprised of a body having an outer surface constructed of a refractory material and including a inner lining of a non-reactive barrier material selected from rhenium, osmium, iridium or mixtures thereof In a preferred embodiment, the non-reactive barrier lining between 0.010″ and 0.050″ in depth.
The present crucible construction provides a number of advantages over the prior art. Particularly, furnaces constructed with rhenium, iridium, and/or osmium lined crucibles produce products with much lower levels of refractory metal in the solution. For example, the metal dissolved in the silica can be reduced to below 10 ppb, preferably below 1 ppb, and preferably below the current level of detection via NAA. This reduced amount of refractory metal contamination in the silica melt improves the chemical composition of the silica glass allowing for a decrease in discoloration and surface haze. Furthermore, utilization of a furnace equipped with a crucible including the non-reactive lining allows operation at optimum temperature ranges. More specifically, the non-reactive crucible allows the furnace to operate at temperatures in excess of 2350° C. Operation at these higher temperatures achieves better fining. Moreover, operation at optimum fusion temperatures will increase solubility of gaseous species in the raw material, thus reducing airline defects in the drawn products. Similarly, the present inventive crucible will also help to further reduce the presence of haze and discoloration in the resultant glass products.
It should be noted that the terms “quartz” and “silica” are used interchangeably throughout this application, both being directed generally to the compound SiO 2 . Similarly, the present invention encompasses the use of any raw material introduced to the melting furnace, including but not limited to natural silica/quartz and synthetic silica.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation and advantages of the present preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a longitudinal sectional view of a furnace of the present invention; and
FIG. 2 is a diagrammatic longitudinal view of an alternative furnace demonstrating use of the present inventive construction in the melt zone of a furnace.
DETAILED DESCRIPTION OF THE INVENTION
In one of its preferred embodiments, the fused quartz product of the present invention can be formed in a furnace configuration having the features shown in FIG. 1 . Moreover, FIG. 1 demonstrates the suitability of the present inventive construction technique in the rebuild of an existing furnace design. More particularly, the furnace has a general cylindrical shape. Preferably, an elongated cylindrical melting crucible 10 constructed of a refractory metal layer 11 , such as tungsten or molybdenum as well as combinations thereof, is used. The melting crucible 10 further includes a lining of rhenium 13 over the refractory metal layer 11 .
A purified sand raw material is fed through a top opening 12 into an upper melting zone 14 of the crucible member. The top opening 12 is provided with movable closure means 16 , such as a trapdoor which can be kept closed except for observing the level of the melt 18 and during feeding of the raw material into the crucible. Automatic feeder means 20 are provided at the top opening of the crucible member to maintain a predetermined level of the raw material in the crucible. The feeder includes a discharge tube 22 having its outlet opening located the crucible 10 so as to provide the raw material in the upper zone where melting takes place, a purge gas inlet tube 24 and reservoir means 26 which contains supply of the raw material being fed automatically to the discharge tube.
Simple gravity flow of the raw material to the melting zone of the crucible member takes place as the melt level in the crucible drops with fusion of the sand particles so that it becomes unnecessary to incorporate any further means to adjust the rate of feeding the raw material as described. The purge gas being supplied to the feeder helps eliminate gases contained in the raw material which could otherwise oxidize the refractory metal components of the crucible member or form bubbles in the fused quartz melt which cannot thereafter be removed or minimized in a manner to be described in part immediately hereinafter. The composition of said purge gas is the same or similar to that admitted elsewhere to the upper zone of said crucible member for the purpose of reducing bubbles and ridges in the final product and which consists of a gas mixture of hydrogen and helium in the volume ratios 40-100% hydrogen and 60-0% helium.
The lower portion 28 (a drawing zone) of the crucible 10 includes an annular ring 30 having central opening 32 through which the elongated fused quartz member is continuously formed by drawing the viscous material through the opening. A core 34 is centrally disposed in the opening 32 and extends below the annular ring as the means of forming tubing from the viscous material being drawn from the melt. As known by the skilled artisan, the position of the core can be shifted as necessary to produce the desired size of extrudate. Support element 35 is affixed to the wall of the crucible and provides rigid support of the core which helps to maintain a constant size opening from which the product is being drawn. The core is fabricated with a hollow interior 36 which is connected to inlet pipe 38 so that supply of non-oxidizing gas having a different composition than supplied to the melting zone of the crucible can be furnished as a forming atmosphere while the tubing 40 is being drawn.
A second inlet pipe 42 supplies the same type forming atmosphere which can be a mixture containing hydrogen in a non-oxidizing carrier gas such as nitrogen in volume ratios 1-20% hydrogen and 99-80% carrier gas as a protective atmosphere which surrounds the exterior wall of the crucible. This supply of forming gas is provided to annular space 44 which provides a housing means for the crucible and includes a central bottom opening 46 providing exhaust means from said cavity for the forming gas in a manner which envelops the exterior surface of the elongated fused quartz member being drawn from the furnace. The exterior wall of the annular space comprises a refractory cylinder 48 which in combination with exterior housing 50 of the furnace construction serves as the container means for the induction heating coils of the apparatus. More particularly, a concentric passageway 52 is defined between the exterior wall of the refractory cylinder 48 and the interior wall of housing 50 in which is disposed two helical-shaped induction heating coils 54 and 56 supplying separate heating sources for the upper and lower zones of the crucible, respectively. Of course, additional coils may be employed as governed by the size of the furnace, for example, it may be beneficial to include additional coil(s) in the finish zone.
The heating sources and the power supplies thereto can be of conventional construction which include electrical conductors that are hollow for water cooling and electrically connected to separate A.C. power supplies for the independent heating utilized in the practice of the present invention. The remainder of the passageway occupied by the coils is preferably packed with a stable refractory insulation such as zirconia in order to conserve heat in the furnace.
A third supply pipe 58 is located in the top section of exterior housing 50 and supplies the same or similar purge gas mixture to the melting zone of the crucible as provided by inlet pipe 24 . The above-described furnace is operated in connection with conventional tube or rod drawing machinery which has been omitted from the drawing as forming no part of the present invention.
Of course, the present inventive use of a non-reactive crucible lining is not limited to the furnace or crucible shown in FIG. 1 . In fact, the use of the non-reactive lining is suitable for use in any furnace/crucible embodiment known to the skilled artisan (e.g. FIG. 2 ).
In accordance carrying out the process of the present invention in the above-described apparatus, a natural silica sand having a nominal particle size of −50 mesh U.S. screen size which has been purified by chemical treatment to the nominal impurity content below is supplied to the top opening of the crucible member in the apparatus.
RAW MATERIAL
Impurity
Natural (p.p.m.)
Synthetic (p.p.m.)
Fe 2 O 3
1
0.07
TiO 2
2
<.02
Al 2 O 3
20
100
CaO
0.4
<.01
MgO
0.1
<.05
K 2 O
0.6
0.1
Na 2 O
0.7
0.1
Li 2 O
0.6
<.05
B
<0.2
—
ZrO 2
<1.0
<.02
The above raw material is provided to the crucible member which has been heated in excess of 2050° C. while also being supplied with the hydrogen and helium gas mixture hereinbefore specified. After a predetermined melt level of fused quartz has been established in the crucible and the molten material caused to flow by gravity through central bottom opening 32 in the crucible member, tubing or rod is then drawn continuously by the drawing machine (not shown) in the presence of a forming gas atmosphere as hereinbefore specified. In any continuous drawing of tubing/rod in the foregoing described manner, the electrical power being supplied to the lower heating coil 56 is typically maintained at a lower level than the electrical power being supplied to the upper heating coil 54 in order to lower the temperature of the material as it is being drawn to below a temperature of 2050° C. However, the inventive use of a non-reactive lining in the finish zone can allow higher temperature operation if desired. The combined effect of these process steps whereby the level of raw material in the crucible is maintained relatively constant while distinct temperature zones are maintained during the drawing operation has been found to permit outside diameter variation in the drawn product to less than about ±3% over various sizes of tubing.
As stated above, the internal surface of the furnace crucible 10 includes a rhenium, osmium or iridium sheet or coating 13 . The coating 13 may be applied to the refractory metal layer 11 by chemical vapor deposition, electrolysis, plasma spray or any other technique known to the skilled artisan (hereinafter referred to as “chemical bonding”). The non-reactive layer 13 may also be physically attached to the refractory metal layer 11 by attaching a sheet directly to the wall of the crucible with rivets, bolts, screws, etc., preferably constructed from the same or similar material as the non-reactive lining itself Alternatively, a properly shaped rhenium sleeve can be inserted into the crucible. In fact, a combination of coating or lining methods may be used depending on the geometric complexity of the segments comprising the crucible assembly.
Referring now to FIG. 2, the application of the present inventive coating applied only to the melt/fusion zone is demonstrated. Moreover, a coating of rhenium 113 is applied in the melt/fusion zone 115 on the inner wall 117 of the crucible 119 . In this manner, the most advantageous high temperature area (the melt zone) is protected from tungsten/molybdenum contamination by the barrier layer.
EXAMPLES
Several furnace experiments using rhenium lining or coatings were performed. Furnaces used in these experiments were equipped with tungsten crucibles to which rhenium lining was attached by a combination of screws or rivets and also by plasma spray coat. Various tube products drawn during the tests were analyzed to determine levels of contamination. Results of neutron activation analysis (NAA) and x-ray florescence surface analysis (XRF) show significant differences in levels of tungsten concentration in samples of tubing made from lined and unlined furnaces. See more particularly, the following table.
Without Coating or Liner
With Rhenium
Type of
NAA, W ppb
XRF, W ppm
NAA, W ppb
XRF,
tubing
W ppm
Natural
14 to 20
<5
Silica
Synthetic
10 to 30
0.2 to 1.0
silica
Accordingly, it has been demonstrated that the present invention achieves a reduction in contamination of the fused silica product. The resultant benefits described above are therefore achieved.
While the invention has be described by reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements without departing from the scope of the invention. In addition, any 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 embodiment disclosed as the best mode contemplated for carrying out this invention, but the invention will include all embodiments falling within the scope of appended claims.
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A crucible for melting a silica for fusion of said silica into a desired shape. The crucible having a main body with inner and outer surfaces comprised of a refractory material. In addition, at least a portion of the inner surface includes a barrier layer comprised of a material selected from rhenium, osmium, iridium, and mixtures thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a division of application Ser. No. 10/515,580, filed on Nov. 23, 2004, which is the national phase of International Application No. PCT/US2003/016885, filed on May 27, 2003, claiming the benefit of Provisional Application No. 60/382,964, filed on May 24, 2002. The entire contents of these earlier applications are incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to wicking, antibacterial/bacteriostatic/antifungal, (hereinafter referred to as antibacterial/antifungal, antibacterial/bacteriostatic, or antibacterial/bacteriostatic/antifungal), and low friction apparel and methods for producing same, such as clothing, fabrics and the like. More particularly, the invention relates to wicking, antibacterial/antifungal, low friction apparel which incorporates fabrics or chemicals which wick, have antibacterial/antifungal properties and low coefficient of friction either overall or in specific areas of the apparel that will minimize the development of irritation of a person's skin and related bacterial and fungal infections. The invention also includes methods for producing the wicking, antibacterial/antifungal and low friction apparel and methods for using wicking, antibacterial/antifungal and low friction materials to reduce moisture, friction and the resulting bacterial and fungal infections due to skin moisture and irritation. More particularly, the invention relates to apparel, which incorporates fabrics or chemicals having antibacterial/antimicrobial, wicking, and low friction coefficient of friction properties either overall, or in specific areas of the apparel that will minimize the development of irritation of an apparel wearer's body surface. The invention also includes methods for producing the antibacterial/antifungal, wicking and low friction apparel and methods for using antibacterial/antifungal, wicking and low coefficient of friction materials to reduce irritation and infections.
[0003] The invention relates to apparel with an interior wicking surface against the skin that also has antibacterial/antifungal properties with an exterior low friction surface and methods for producing same. More particularly, the invention relates to apparel with a wicking surface against the skin which incorporates fibers or chemicals that have antibacterial/antifungal properties and a low friction outer surface which incorporates fibers or chemicals having a low coefficient of friction either overall or in specific areas of the apparel, such that the wicking, antibacterial/antifungal surface will be on the interior of the apparel and the low friction surface will be presented on the exterior of the apparel.
BACKGROUND OF THE INVENTION
[0004] Skin when rubbing against another surface of skin causes irritation, breaks down and becomes irritated. Perspiration is usually also present in areas where skin rubs together. Intertrigo, or a rash in body folds, develops. Affected skin is reddened and uncomfortable. Body folds are prone to inflammatory rashes because the skin has a relatively high temperature, moisture from insensible water loss and sweat cannot evaporate, and friction from movement of adjacent skin results in chafing. Bacteria, fungus and yeasts, which are normally resident on the skin, multiply in such environments and may result in further damage to the skin.
[0005] It can appear anywhere two skin surfaces lie next to each other and rub together, but most often occur in the skin folds of the groin, the inner thigh area, underarms, between the ribs, and under and between the breasts. This condition is most common in warm climates and during the summer months. Intertrigo will appear as a reddish color rash that might be sore or itchy. It normally progresses gradually, starting as a mild chafing, then slowly, with continued exposure to moisture and friction, develops into a persistent itchy rash. Sometimes a secondary bacterial or fungal infection may occur, causing the formation of pustules and weeping and oozing of the skin, as well as severe itching and pain. Severe Intertrigo on the groin or thighs can limit or affect mobility. Intertrigo primarily affects overweight people who perspire heavily and people with diabetes. It can also occur in any individual where fat distribution causes two surfaces of the skin to rub together. Persons who suffer from urinary incontinence are at increased risk of developing Intertrigo in the groin area. Once a person develops Intertrigo it is usually chronic and reoccurring.
[0006] Previous patents have addressed part of the problem, that is, the addition of fibers with low co-efficient of friction into apparel to reduce friction. Or, conversely, patents exist which only address wicking properties, especially garments designed for incontinence problems. In doing so, they only addressed part of the problem with skin irritation. None have addressed both factors, that is, moisture and friction as being the causative agents for creating Intertrigo. Prior art has failed to combine wicking and low friction materials to solve the problem and with obesity becoming an epidemic world wide a solution to this problem is important.
[0007] Robert T. Gunn's U.S. Pat. Nos. 5,752,278, May 19, 1998, 5,829,057, Nov. 3, 1998, and 5,752,278, May 19, 1998 acknowledge that irritation is caused by moisture and friction. He states, “the addition of low friction material to the fiber, yarn, fabric or article can also be useful to wick away moisture from the skin to help guard against irritation as well as wetness.” However, according to the DuPont Technical Information brochure, TEFLON® PTFE, Properties, Processing, and Applications, which he makes reference to, the moisture regain percentage for TEFLON® is 0.0%. All of the garments heretofore known suffer from a number of disadvantages:
[0008] Since irritation of the skin is known to result from moisture and friction, the addition of a fiber with 0.0% moisture absorption properties while serving to facilitate wicking would not work as efficiently as a fiber whose sole function is to wick and absorb perspiration.
[0009] Gunn's patent's primarily teach the addition of low friction materials which are incorporated into both sides of the material. When he teaches plating as a method, he only includes weaving, not knitting, as the preferred method.
[0010] Gunn's patents include apparel with seams in the inner thigh area. The addition of seams in the inner thigh area causes irritation of the skin. His patent does not address the addition of an inner thigh panel or circular knitting techniques, which eliminate seams altogether, as a preferred method of constructing a garment. His solution is the addition of low friction fibers to the seams instead of the elimination of seams altogether in this area.
[0011] Gunn's patents do not add any fiber or chemical which are antibacterial/antifungal into the garment to help with infections that are secondary to skin irritation once moisture and friction are present.
[0012] Gunn's patents teach the use of low friction materials on the exterior of both sides of the inner surfaces of the thigh areas. This method can be used, however, exterior plating on one surface of the inner thigh area is sufficient to reduce friction on both surfaces and he does not teach this.
OBJECTS AND ADVANTAGES
[0013] Apparel is made out of many materials, natural and man-made as well as blends. They can be natural such as cotton, silk, linen, or leather. They can also be man made such as nylon, vinyl, spandex, polyester, TEFLON®, rayon, or any combination of natural or manmade fibers.
[0014] Accordingly, several objects and advantages of my invention are:
[0015] the addition of a layer of wicking fibers or chemicals to the interior surface of the apparel to absorb all perspiration to keep the skin dry.
[0016] the addition of antibacterial/antifungal fibers or chemicals into the moisture absorption layer of the apparel to protect the skin from infections.
[0017] the method of plating wicking fibers on the interior surface, with antibacterial/antifungal properties, and low friction fibers on the exterior surface instead of the fibers all being woven together.
[0018] the method of knitting instead of weaving as the preferred method of plating the fibers since knitted garments contour to the body more easily and cause less friction because they conform more.
[0019] the method of constructing the garments on a circular knitting machine as a way of avoiding seams, especially in the inner thigh or underarm areas, as the preferred method of constructing the garments. Or, the method of sewing a plated panel or gusset with wicking, antibacterial/antifungal and low friction properties into the garment, for example, in the inner thigh or underarm areas, which eliminate seams in these areas.
[0020] the addition of antibacterial/antifungal fibers or chemicals into the garment to help with infections that are secondary to skin irritation once moisture and friction are present.
[0021] the use of low friction materials on only one, versus both, exterior surface of the inner thigh areas or underarm areas, to reduce friction between the legs, or under the arms, as a means of cutting down heat and friction between the legs, or under the arms. TEFLON® and other low friction fibers, such as nylon, are high heat retention fibers. Thus, to only plate one side of an area in apparel where two sides oppose each other, for example, one side of the inner thigh area, for example, the right side, where the left side is not plated, or one side of the underarm area, for example the top or bottom portion of the gusset with the opposite area not being plated, would be an added advantage in terms of heat reduction.
[0022] the use of low friction materials, which are costly, on one side only of an inner thigh or underarm area, would significantly reduce costs for manufacturers and consumers.
[0023] It would be highly desirable to have apparel which has a wicking, anti-bacterial/antifungal inner layer plated with an exterior low friction material in areas of high body surface contact such that irritations and the secondary skin infections are avoided.
SUMMARY OF THE INVENTION
[0024] It is the principle object of the invention to is provide wicking, antibacterial/-bacteriostatic/antifungal, low friction apparel which avoids or minimizes the development of skin irritations due to moisture and friction which can lead to the development of skin infections.
[0025] From the description above, my knit sewn in leg panel, a cut and sew leg panel, gussets, or a plated area in a circular knit method has the additional advantages in that:
[0026] a further object of the invention is to provide a method for producing the wicking, antibacterial/bacteriostatic/antifungal, low friction apparel by chemically treating the wicking yarns or fibers or the like of the material from which the apparel is made prior to or after production with antibacterial/-bacteriostatic/antifungal chemicals.
[0027] a further object of the invention is to provide a method for producing wicking, antibacterial/bacteriostatic/antifungal, low friction apparel by incorporating wicking, antibacterial/bacteriostatic/antifungal, low friction yarns and fibers into the fabric from which the apparel is made.
[0028] a further object of the invention is to provide a method for producing a wicking, antibacterial/bacteriostatic/antifungal, low friction inner leg panel by incorporating wicking and low friction, antibacterial/bacteriostatic/antifungal, yarns and fibers into the fabric from which the apparel is made.
[0029] a further object of the invention is to provide a method for producing a wicking, antibacterial/bacteriostatic/antifungal, low friction underarm gusset by incorporating wicking and low friction yarns and fibers into the fabric and chemically treating them with antibacterial/bacteriostatic/antifungal chemicals which the apparel includes.
[0030] a further object of the invention is to provide a method for producing a wicking, antibacterial/bacteriostatic/antifungal inner leg panel by incorporating wicking, antibacterial/bacteriostatic/antifungal, yarns and fibers into the fabric from which the apparel is made.
[0031] a further object of the invention is to provide a method for producing a wicking, antibacterial/bacteriostatic/antifungal, gusset by incorporating wicking yarns and fibers into the fabric and chemically treating them with antibacterial/bacteriostatic/antifungal chemicals which the apparel includes.
[0032] a further object of the invention is to provide a method for producing a wicking, antibacterial/bacteriostatic/antifungal, low friction apparel by incorporating wicking, antibacterial/bacteriostatic/antifungal, low friction yarns and fibers into the fabric from which the apparel is made where only one side of the leg panel, that is, the right or left one, or either the top or bottom portion of the underarm gusset, have low friction fibers on the exterior surface.
[0033] a further object of the invention is to provide a method for producing apparel so that the panel or gusset which contains the antibacterial/bacteriostatic/antifungal, low friction yarns and fibers can be incorporated into any type of apparel a manufacturer wishes to make.
[0034] a further object of the invention is to provide a method for producing apparel so that the sewn in inner thigh panel which contains the antibacterial/-bacteriostatic/antifungal, low friction yarns and fibers can be incorporated into any type of apparel a manufacturer wishes independent of a wicking and antimicrobial/bacteriostatic/antifungal gusset.
[0035] a further object of the invention is to provide a method for producing apparel so that the underarm gusset which contains the antibacterial/-bacteriostatic/antifungal, low friction yarns and fibers can be incorporated into any type of apparel a manufacturer wishes independent of a wicking and antimicrobial/bacteriostatic/antifungal leg panel.
[0036] a further object of the invention is to provide a method for producing the wicking, antibacterial/bacteriostatic/antifungal, low friction panels and gussets which can either be utilized on cut and sew garments or in seamless garments should the manufacturer wish.
[0037] a further object of the invention is to provide a method for producing the wicking, antibacterial/bacteriostatic/antifungal, low friction panels and gussets in any type of legwear, be it ready to wear, active wear, hosiery, or any other type.
[0038] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the gusset can have other shapes such as oval, trapezoidal, triangular, etc. The inner leg panels can be tailored to accommodate the various types of garments manufactured and can be made larger or smaller as size determines. It can also have other shapes, such as oval, trapezoidal, etc. The seams can be of any type. The length of the garment can be any type the manufacturer wishes. All parts of the garment may include stretch fibers for memory and shape retention. The amount of spandex can range from as little as 0% to as much as 40% for shapewear. The knits can be of any type such as, but not limited to, warp knits and circular knits. Circular knits, such as jersey knits, are ideal for bodywear, sportswear, and hosiery. Closures may be zippers, VELCRO®, buttons, snaps or any other type of closure the manufacturer wishes to utilize.
[0039] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than the examples given.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the present invention will be better understood from the following description when taken in conjunction with the accompanying drawings in which:
[0041] FIG. 1A is a three-quarter view of an ankle length seamless garment worn by a person in accordance with the teachings of this invention.
[0042] FIG. 1B is a representation of both the front and back views of FIG. 1A that are identical.
[0043] FIG. 1C is a side view of the garment as shown in FIG. 1A .
[0044] FIG. 2 is a view of a circular knit tube used to construct the seamless garment in FIGS. 1A , 1 B, 1 C and FIG. 8 .
[0045] FIG. 3 is the front and back views of the circular knit tube showing the center cut lines, that when cut, forms the leg portions of the garment.
[0046] FIG. 4 is a perspective view of cut circular knit tube in FIG. 3 showing the torso and leg portions which are attached to the sewn in leg panel 38 , comprised of sides 38 a and 38 b.
[0047] FIG. 5 is an enlarged detail of sewn in panel in FIGS. 1A , 1 B, 1 C, and FIG. 8 that is attached to the circular knit tube in FIG. 4 to form the garment.
[0048] FIG. 6 is a cross section taken through section lines 6 - 6 on FIG. 5 .
[0049] FIG. 7A is a cross section taken through section lines 7 - 7 on FIG. 5 .
[0050] FIG. 7B is an alternate method of construction for the cross section taken through section lines 7 - 7 on FIG. 5 .
[0051] FIG. 8 is a perspective view of the sewn in leg panel in FIGS. 1A , 1 B, and 1 C.
[0052] FIG. 9 is an enlarged detail of leg stitches and hem in FIG. 1A , 1 B, 1 C and FIG. 8 .
[0053] FIG. 10 is a three-quarter view of an ankle length “cut and sew” garment, worn by a person, in accordance with the teachings of this invention.
[0054] FIG. 11A is the right pattern piece of a “cut and sew” garment.
[0055] FIG. 11B is the left pattern piece of a “cut and sew” garment.
[0056] FIG. 12 is a view of the front and back pattern pieces of a “cut and sew” garment sewn together, front to back, in the torso area.
[0057] FIG. 13 is a perspective view of the “cut and sew” garment in FIG. 12 showing the torso and leg portions that are to be attached to the “cut and sew” sewn in leg panel.
[0058] FIG. 14 is an enlarged detail of “cut and sew” sewn in panel in FIG. 10 that is attached to the “cut and sew” garment in FIG. 13 to form the garment.
[0059] FIG. 15 is a perspective view of FIG. 10 .
[0060] FIG. 16A is a three-quarter view of a maternity seamless garment worn by a woman with a midriff waistline that is below the knee length.
[0061] FIG. 16B is a three-quarter view of a seamless garment worn by a man with a natural waistline, is above the knee length, has a separate sewn on waistband, and a fly front closure.
[0062] FIG. 16C is a three-quarter view of a seamless garment, worn by a woman, with a turtleneck styled collar, long sleeves, and front zipper closure.
[0063] FIG. 17A is a three-quarter view of a “cut and sew” garment worn by a woman with a bikini waistline, is ankle length, and has oblique below the knee seaming for the “cut and sew” sewn in panel.
[0064] FIG. 17B is a three-quarter view of a “cut and sew” garment worn, by a woman, with a separate sewn on waistband at the natural waistline, and is a boy cut length.
[0065] FIG. 18A is a three-quarter view of a pair of pantyhose, with a plated area on the inner thigh area, a plated crotch, and a plated bottom and sides of a foot.
[0066] FIG. 18B is a perspective view of a pair of pantyhose with a plated area on the inner thigh area, a plated crotch, and a plated bottom and side of a foot.
[0067] FIG. 19A are seamless knit tubes with plated wicking inner thigh sections and a plated bottom and sides of a foot.
[0068] FIG. 19B is a cross section taken through section lines 19 b - 19 b on FIG. 19A .
[0069] FIG. 19C are the knit tubes, cut in the torso area, with plated wicking inner thigh sections, and plated bottom and sides of feet.
[0070] FIG. 19D is the cut knit tubes, stitched together in the torso area, with plated wicking inner thigh sections, hemmed toes, and the unattached plated crotch gusset.
[0071] FIG. 19E is a cross section taken through section lines 19 e - 19 e in FIG. 19D .
[0072] FIG. 19F is an alternate method of construction for the cross section taken through section lines 19 e - 19 e on FIG. 19 D.
[0073] FIG. 19 G is an alternate method of construction for the cross section taken through section lines 19 b - 19 b on FIG. 19A .
[0074] FIG. 20A is an above the knee circular knit garment with a plated inner thigh area.
[0075] FIG. 20 B is a cross section through the plated inner thigh area.
[0076] FIG. 20C is a cross section through the plated crotch gusset.
[0077] FIG. 20D is an alternative method of constructing the cross section taken through section lines 20 c - 20 c.
[0078] FIG. 21 is a plated bra.
[0079] FIG. 22 is a plated knit skirt garment.
[0080] FIG. 23 is a plated knit above the knee garment.
[0081] FIG. 24 is a garment with a plated underarm area.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Description FIGS. 1 - 9
[0082] The novel features of the present invention are incorporated and illustrated in FIGS. 1A , 1 B, 1 C and FIG. 8 . In general, the present invention is shown generally as a “seamless” washable garment 20 . It is an improvement over prior garments for both men and women whether they are classified as underwear, shaping garments, hosiery, athletic garments, or ready-to-wear. A person 28 is wearing the garment 20 and comprises numbers 21 through 70 . For purposes of clarity, like reference numerals are used where appropriate. The garment 20 is comprised of a torso portion 23 having a waistband 22 with a top 56 and a stitching line 58 , a front portion 24 , and a back portion 26 . Further, the garment 20 contains a pair of leg portions of the garment 39 that are connected at a perforated line 30 and extend downwardly to the feet 49 of the person 28 wearing the garment 20 . A region of the angle formed by the junction of the legs or crotch 32 and an inner part of the leg 40 is covered by a knit sewn in leg panel 38 . Knit sewn in leg panel 38 is comprised of a crotch portion of sewn in panel 34 , and an inner leg portion of knit sewn in leg panel 36 that will be further described in FIG. 5 , FIG. 6 , and FIG. 7 . A front leg panel seam 42 connects the knit sewn in leg panel 38 to the torso portion of the garment 23 and to the leg portion of the garment 39 which in total forms garment 20 . Alternating five rows of jersey stitches 44 and five rows of diamond-patterned stitches 46 are above the hem seam 48 that help hold the garment in place. First and second leg openings of the hem 50 a and 50 b respectively allow for an opening for the foot 49 .
[0083] An important aspect of this invention is to provide the garment with the knit sewn in leg panel 38 , which is generally shown in FIGS. 1A , 1 B, 1 C and FIG. 8 , that eliminates an inner thigh seam, as being disposed of crotch portion 34 and an inner leg portion of knit sewn in leg panel 36 . Knit sewn in leg panel 38 is sewn into garment 20 so as to overlay the inner part of leg 40 and crotch 32 of the person 28 . The relative position of knit sewn in leg panel 38 is to cover the inner part of the leg 40 and is comprised of yarns that have stretch, wicking, friction reduction and antibacterial, antifungal, and or antimicrobial characteristics and will be further described in FIG. 5 , FIG. 6 and FIG. 7 .
[0084] The criteria for wicking yarns or fibers are as follows: Tactel®, a type of wicking yarn is used on the inside of the plated area and Tactel®, cotton, polyester, viscose, and or wool, for example, would be utilized on the outside of the plated areas. Or, a yarn or fiber with a higher DPF, denier per filament, is plated on the inside of a fabric, and a yarn or fiber with a lower DPF, is plated on the outside of a surface of a fabric. The higher DPF material has fatter, larger filaments and the lower DPF material has more smaller, thinner filaments. As a result the moisture on the inside of a person's skin is wicked away by the material with the larger DPF to the surface of the fabric with the lower DPF. The surface of the wetted area on exterior surface of the garment is greater than the surface of the wetted area on the inside. The result is that a person's skin stays dry.
[0085] Another method of producing wicking would be to plate fibers or yarns with different shapes together. For example, if moisture is on a person's skin, it will wick from a surface comprised of yarns or fibers that has few “lobes” or “clover leafed” shapes into a surface which is comprised of yarns or fibers that have many “lobes” or “clover leafed” shapes. The surface of the wetted area on the exterior surface of the garment is greater than the surface of the wetted area on the inside. The result is that a person's skin stays dry.
[0086] FIG. 1B is a representation of both the front and back views of FIG. 1A that are identical.
[0087] FIG. 1C is a side view of the garment as shown in FIG. 1 .
[0088] FIG. 2 represents a circular knit tube 52 out of which the seamless garment 20 is constructed. It is comprised of a top of circular knit tube 54 , a top of the folded over waistband 56 , and a waistband seam 58 . A bottom of the circular knit tube 60 is folded up to hem seam 48 to form the first and second leg openings of hem 50 a and 50 b respectively. Alternating five rows of jersey stitches 44 and five rows of diamond-patterned stitches 46 are above the hem seam 48 that helps hold the garment in place but are at the manufacturers discretion and can be omitted or an alternative method for hemming the garment can be used.
[0089] FIG. 3 represents the front and back views of the circular knit tube 52 showing the front and back center cut lines that are identical 62 , that forms the leg portion 39 of the seamless garment 20 shown in a perspective view in FIG. 4 .
[0090] FIG. 4 is a perspective view of cut circular knit tube in FIG. 3 showing the torso portion 23 and leg portions 39 of the garment 20 . The torso portion 23 shows a folded over waistband 22 with a top 56 and a seam 58 . The leg portions 39 have bottoms of the circular knit tube 60 a and 60 b which are folded up to hem seams 48 a and 48 b to form the first and second leg openings of hem 50 a and 50 b respectively after the knit sewn in leg panel 38 has been sewn in place. This will be further explained in FIG. 5 . There is a crotch area 32 in between the leg portions of the garment 39 . Alternating five rows of jersey stitches 44 and five rows of diamond-patterned stitches 46 are above the hem seam 48 , which help hold the garment in place. The circular knit tube sides represented by 52 a and 52 b are for sewing purposes and are to be attached to sides of knit sewn in leg panel 38 a and 38 b to form the front and back leg panel seams 42 that are identical to form garment 20 .
[0091] FIG. 5 is an enlarged detail of knit sewn in panel 38 in FIGS. 1A , 1 B, 1 C and FIG. 8 . The inner leg portion of knit sewn in leg panel 36 consists of a lower portion from an area from the ankle to above the knee 36 a , and an upper portion from above the knee to the crotch area 36 b . The crotch portion of sewn in panel 34 is smaller due to increased tension of the stitches in the crotch area 32 . The tapering shape of the sewn in leg panel is dependent on the length of the garment but designed to cover an area of the inner part of the leg 40 . Together both the inner leg portion of sewn in leg panel 36 and crotch portion 34 comprise the knit sewn in leg panel 38 . Section lines 6 - 6 represent cross sections through the plated yarns in the upper portion of inner leg portion of the knit sewn in panel from an area above the knee to crotch 36 b and will be further described in FIG. 6 . Section lines 7 - 7 represent cross sections through the plated yarns in the crotch portion of the knit sewn in panel 34 and will be further described in FIG. 7 . Hem seam 48 a and 48 b and the bottoms of the sewn in leg panel 64 a and 64 b form the first and second leg openings of the hem 50 a and 50 b . When the sides of sewn in knit panel 38 a and 38 b are sewn into the cut circular knit tube sides 52 a and 52 b the garment 20 is hemmed on the hem seams 48 a and 48 b.
[0092] FIG. 6 is an enlargement of a cross section taken through section lines 6 - 6 in FIG. 5 . An outer friction reducing yarn or fiber 66 is plated, (a knit fabric which has one kind of yarn on the face while another type is found on the back of the goods), over an inner wicking yarn or fiber 68 . The placement of the yarns can also be accomplished by cutting the knit sewn in leg panel 34 from a woven double-faced fabric. The antifriction yarn is on the exterior of the garment and the wicking face is on the interior of the garment. An illustrative example of the friction reducing yarn may take the form of DuPont's® Teflon®, silicone, graphite, KYNAR ‰ boron, polypropylene, polyethylene, and GORETEX®. An illustrative example of a wicking yarn may take the form of DuPont's® Coolmax® and Aquator® fibers. The resulting knit fabric that makes up the knit sewn in leg panel 38 that is worn against the person's 28 skin. The wicking yarn 68 can be chemically treated to be antibacterial, antifungal, and bacteriostatic. To save the manufacturer money, the friction reducing yarn 66 can be plated on one side of the upper portion of the inner leg portion of the sewn in panel 38 to save money for the consumers without losing a decrease in function for the wearer.
[0093] FIG. 7A is an enlargement of a cross section taken through section lines 7 - 7 in FIG. 5 . An outer antibacterial, antifungal or bacteriostatic yarn or fiber 70 is plated over an inner wicking yarn or fiber 68 . An illustrative example of the antibacterial, antifungal, and bacteriostatic yarn or fiber is Merrill's Skin Life®. The resulting knit fabric which makes up the crotch portion of sewn in panel 34 in knit sewn in leg panel 38 is worn against the person's 28 skin. The wicking yarns or fibers can be chemically treated to be antibacterial. antifungal or bacteriostatic and the antibacterial, antifungal, and bacteriostatic yarn eliminated to save money.
[0094] FIG. 7B is an alternate method of construction for the cross section taken through section lines 7 - 7 on FIG. 5 . An antibacterial, antifungal or bacteriostatic yarn or fiber 70 is knit with an inner wicking yarn or fiber 68 . These two yarns are then plated with an outer friction reducing yarn or fiber 66 . An illustrative example of the antibacterial, antifungal, and bacteriostatic yarn or fiber is Merrill's Skin Life®. The resulting knit fabric which makes up the crotch portion of sewn in panel 34 in knit sewn in leg panel 38 is worn against the person's 28 skin The wicking yarns or fibers can be chemically treated to be antibacterial, antifungal, and bacteriostatic and the antibacterial, antifungal, and bacteriostatic yarn eliminated to save money.
[0095] A perspective view of the sewn in leg panel 38 in FIGS. 1A , 1 B, and 1 C is represented in FIG. 8 . It is achieved by sewing the cut circular knit tube in FIG. 4 to the knit sewn in leg panel 38 in FIG. 5 . Side 52 a of the cut circular knit tube 52 is sewn to side 38 a of the knit sewn in leg panel 38 and side 52 b of the cut circular knit tube 52 is sewn to side 38 b of the knit sewn in leg panel 38 to form seams 42 that are identical front and back. The garment is finished when the first and second leg openings of hem 50 a and 50 b are hemmed. This is accomplished by turning up the bottom of circular knit tube 60 , 60 a and 60 b , and the bottoms of sewn in leg panel 64 a and 64 b and sewn on the hem seam 48 . A first and second leg opening of hem 50 a and 50 b are thus formed. A detail of leg stitches and a leg opening of hem 50 is shown in FIG. 9 .
[0096] FIG. 9 is an enlarged detail of leg stitches and hem in FIG. 1A , 1 B, 1 C and FIG. 8 . Five rows of jersey stitches 44 and five rows of diamond patterned stitches 46 alternate and help hold the garment 20 in place. The stitches are not necessary for the function of the garment and are at the manufacturer's discretion. The lower portion of the inner leg panel from the ankle to above the knee 36 a covers the inner part of the leg 40 at the leg panel seam 42 . The hem seam 48 creates the leg openings of the hem 50 .
Description FIGS. 10 - 15
[0097] An additional embodiment is shown in FIG. 10 . In this case the garment 120 is shown as a “cut and sew” garment with a “cut and sew” sewn in leg panel 138 . The novel features of the “cut and sew” example of the present invention are incorporated and illustrated in FIGS. 10 , 11 A, 11 B, 12 , 13 , 14 , and 15 . In general, the present invention is shown generally as a “cut and sew” washable garment 120 . It is an improvement over prior garments for both men and women whether they are classified as underwear, shaping garments, hosiery or as athletic garments. A person 128 is wearing the garment 120 and comprises numbers 122 through 170 . For purposes of clarity, like reference numerals are used where appropriate. The garment 120 is comprised of a torso portion 123 having a waistband 122 with a top 156 and a stitching line 158 , a front portion 124 , and a back portion 126 . Further, the garment 120 contains a pair of leg portions of the garment 139 that are connected at a perforated line 130 and extend downwardly to the foot 148 of the person 128 wearing the garment 120 . A region of the angle formed by the junction of the legs or crotch 132 and inner parts of the leg 140 is covered by a “cut and sew” sewn in leg panel 138 . “Cut and sew” sewn in leg panel 138 is comprised of a crotch portion of sewn in panel 134 and an inner leg portion of the “cut and sew” sewn in panel 136 that will be further described in FIG. 14 . The garment 120 has a torso center front and back seams 127 a and 127 b respectively. A front and back leg panel seams 142 a and 142 b respectively connects the “cut and sew” sewn in leg panel 138 to the torso portion of the garment 123 and to the leg portion of the garment 139 a and 139 b , right and left respectively, which in total forms garment 120 . Leg openings of hem 146 are formed when the hem of the pattern pieces of the garment 162 and the hem of “cut and sew” sewn in panel 164 and stitched to the hem seam 144 .
[0098] An important aspect of this invention is to provide the garment with the “cut and sew” sewn in leg panel 138 , that eliminates the need for an inner thigh seam, which is generally shown in FIG. 10 as being disposed of crotch portion 134 and an inner leg portion of sewn in panel 136 . “Cut and sew” sewn in leg panel 138 is sewn into garment 120 so as to overlay the inner part of leg 140 and crotch 132 of the person 128 . The relative position of the “cut and sew” sewn in leg panel 138 is to cover the inner part of the leg 140 and is comprised of materials that have stretch, wicking, friction reduction, and antibacterial or antimicrobial characteristics and will be further described in FIG. 14 .
[0099] FIG. 11A and FIG. 11B are a representation of the front and back views of the pattern pieces used to construct the “cut and sew” garment 120 in FIG. 10 and FIG. 15 that are identical. The front of the pattern piece 150 of “cut and sew” garment 120 and the back of the pattern piece 152 of “cut and sew” garment 120 are comprised of “cut and sew” pattern piece top, 154 a and 154 b , representing front and back respectively. Top of folded over waistband, 156 a and 156 b , representing front and back respectively and the waistband seam, 158 a and 158 b ; representing front and back respectively, comprise the waistband. Both the right pattern piece FIG. 11A and the left pattern piece FIG. 11B have front and back sides to them. The fronts of the pattern pieces 124 of “cut and sew” garment 150 are comprised of two portions, the torso front portion of pattern pieces 124 a and the leg front portions of pattern pieces 124 b . The backs of the pattern pieces 126 of “cut and sew” garment 152 are comprised of two portions, the torso back portions of pattern pieces 126 a and leg back portions of pattern pieces 126 b . Both pattern pieces have a hem seam 144 , a leg opening of hem 146 , and a bottom of pattern pieces, 160 a and 160 b , representing front and back respectively.
[0100] Sewn together front and back pattern pieces without the sewn in leg panel 125 is represented in FIG. 12 . The garment is comprised of the same elements that are contained in FIG. 11A and FIG. 11B . The only additional components are torso center front and back seam, 127 a and 127 b respectively. The front seam 127 a holds the front portions of pattern pieces 124 a together. The torso center back seam 127 b hold the back portion of pattern pieces 126 a together.
[0101] A perspective view of the sewn together front and back pattern pieces without the sewn in leg panel 125 is represented in FIG. 13 . It is achieved by sewing the front portions of pattern pieces, 124 a and 124 a of FIG. 11A and FIG. 11B respectively together at the torso center front 127 a as well as the back portion of pattern pieces 126 a and 126 b respectively to form the torso center back seam 127 b . In this view the folded over waistband 122 , 122 a and 122 b representing front and back respectively, is created when the top of folded over waist and 156 a and 154 b , representing front and back respectively, is folded over and is sewn down on the waistband seam, 158 a and 158 b representing front and back respectively. The torso portion of garment 123 and the leg portions of the garment 139 a and 139 b , right and left respectively, comprise the “cut and sew” garment 121 . The front leg openings 124 b and the back leg openings 126 b are the areas the “cut and sew” sewn in leg panel 138 is to be attached. The other parts are identical to those previously described in FIG. 11A and FIG. 11B .
[0102] FIG. 14 is an enlarged detail of “cut and sew” sewn in panel 138 in FIG. 10 , and FIG. 15 . The inner leg portion of sewn in panel 136 consists of a lower portion from an area above the ankle to the knee 136 a and an upper portion from above the knee to the crotch area 136 b that are stitched together at seam 168 . The crotch portion of sewn in panel 134 connects the leg portions of the “cut and sew” sewn in panels 136 . The upper portion from above the knee to the crotch area 136 b is sewn to the crotch panel 134 by the seams represented by 170 . Together both the inner leg portion of the “cut and sew” panel 136 and crotch portion 134 comprise the “cut and sew” sewn in leg panel 138 the sides of which are represented by 138 a and 138 b for sewing purposes. The tapering shape of the sewn in leg panel is dependent on the length of the garment but designed to cover an area of the inner part of the leg 140 and eliminates an inner thigh seam. The panel sections from the ankle to above the knee 136 a are comprised of the same material as the body of the garment and are connected to an upper portion from above the knee to the crotch area 136 b by a seam 168 . The seam 170 holds the upper portion of “cut and sew” leg panel 136 b to the crotch portion of the panel 134 .
[0103] The panel sections from above the knee to the crotch area 136 b are comprised of a knit plated or knit double-faced fabric that wicks on the inside and is slick on the exterior of the garment. The slickness of the exterior reduces friction between the legs for the wearer. The crotch portion of sewn in panel 134 is comprised of a wicking material that is treated with an anti-bacterial, antifungal and or bacteriostatic chemical to reduce infections and odors for the wearer. Or, it is plated as well, with a wicking fiber on the inside and an anti-bacterial, antifungal or bacteriostatic fabric on the outside. In both the upper portions from above the knee to the crotch area 136 b and the crotch panel 134 the wicking yarns can be chemically treated to be antibacterial, antifungal, and bacteriostatic. To save money for the manufacturer, the friction reducing yarn can be plated on one side only of the upper portion from above the knee to the crotch area 136 b to save money for the manufacturer and the consumer without loosing a decrease in function for the wearer. The hem seam of “cut and sew” panel 162 , leg opening of “cut and sew” sewn in panel 164 and bottom of “cut and sew” sewn in leg panel 166 finish the sewn in leg panel 138 .
[0104] A perspective view of the sewn in leg panel 138 in FIG. 10 is represented in FIG. 15 . It contains all of the elements as in FIG. 10 . The garment 120 is made by sewing together front and back pattern pieces shown in FIG. 13 to the sewn in leg panel shown in FIG. 14 . Leg front portions of pattern pieces 124 b of the sewn together front and back pattern pieces without the “cut and sew” sewn in leg panel 125 are sewn to side 138 a of the “cut and sew” sewn in leg panel 138 . Leg back portions of pattern pieces 126 b of the sewn together front and back pattern pieces without the “cut and sew” sewn in leg panel 125 are sewn to side 138 b of the “cut and sew” sewn in leg panel 138 . This forms the front and back leg panel seams 142 . The garment is finished when the bottoms of pattern pieces 160 and the bottom of “cut and sew” sewn in leg panel 164 are turned up and sewn down on the hem seam 144 and on the hem seam of “cut and sew” sewn in leg panel 162 to create the leg opening of hem 146 .
Description of FIGS. 16 A- 17 B
[0105] The knit sewn in leg panel 38 and the “cut and sew” sewn in leg panel 138 can be made part of any type of garment whether it is seamless or “cut and sew” and there are various possibilities regarding the design of the garments that can utilize the sewn in leg panel 138 whether of a knit or “cut and sew” construction.
[0106] Some examples of the types of garments that can utilize the knit seamless sewn in leg panel are represented in FIGS. 16A-16C . Unless stated otherwise they contain the elements as in FIGS. 1-A , 1 -B 1 -C, and 10 previously identified.
[0107] A three-quarter view of a maternity seamless garment worn by a woman, with a waistline 22 in the midriff area, and is below the knee length is represented in FIG. 16A . A three-quarter view of a seamless garment worn by a man with a natural waistline 22 , is an above the knee length, has a separate sewn on waistband 35 , and a fly front closure 25 is represented in FIG. 16B . A three-quarter view of a seamless garment worn by a woman with a plated turtleneck styled collar 21 has been added to the garment that is the same construction as the knit sewn in leg panel 38 , a turtleneck seam 74 , long sleeves 29 attached to the garment 20 by a armhole seam 72 and front zipper closure 27 is represented in FIG. 16C . A plated underarm gusset 37 has been added to the garment that is the same construction as the knit sewn in leg panel 38 comprised of the chemically treated antibacterial or antimicrobial wicking and friction reduction yarns or fibers.
[0108] The “cut and sew” sewn in leg panel 138 can also be utilized in “cut and sew” garments as represented in FIGS. 17A and 17B . Unless stated otherwise they contain the elements in FIGS. 10 and 15 previously identified.
[0109] A three-quarter view of a “cut and sew” garment worn by a woman with a waistline 22 in the “bikini” position, is ankle length, and has an oblique below the knee seam 168 detail on the “cut and sew” sewn in leg panel 138 is represented in FIG. 17A .
[0110] A three-quarter view of a “cut and sew” garment worn by a woman with a natural waistline, and is a boy cut length with a separate sewn on waistband 35 is represented in FIG. 17B .
Description of Style Options
[0111] The FIGS. 16A-17B illustrate the point that the knit sewn in leg panel 38 and the “cut and sew” leg panel 138 can be sewn into any type of garment whether classified as underwear, shaping garments, athletic or ready-to-wear. Two methods can be utilized to construct them. The first method is to knit a antibacterial, antifungal and or bacteriostatic yarn or fibers 70 with an inner wicking yarn or fiber 68 together with a friction reducing yarn or fiber 66 so that the wicking/antibacterial, antifungal, antimicrobial layer is against the skin and the friction reducing yarn or fiber is on the outer surface of the garment 120 . The second method is to knit the wicking yarn or fiber 68 together with a friction reducing yarn or fiber 66 so that the wicking layer is against the skin and the friction reducing yarn or fiber is on the outer surface of the garment 120 . The wicking yarns can then be chemically treated to be antibacterial, antifungal, and or bacteriostatic. Garments can have any style of waistband whether a folded over waistband 22 or separate sewn on waistband 35 . The placement of the waistband determines the “design style” of the garment. Examples of waistband 22 or separate sewn on waistband 35 placement include “bikini”, “tanga”, “French cut”, “midriff style”, “American”, “natural”, “Japanese” or any placement variation thereof. If the garment 20 is “seamless” and has a waistband 22 , it can be knit into the garment 20 , folded over and hemmed. The waistband 22 can also be knit into the garment with a different type of stitch construction and the top edge of the waistband 22 can be finished on the knitting machine If the garment 20 is a “cut and sew” type the waistband 22 is folded over and sewn down forming a casing. This type of waistband 22 may or may not contain elastic or any other type of stretch materials. On both types of garment 20 , “seamless” and “cut and sew”, the waistband can also be sewn on separately. When a separate sewn on waistband 35 is sewn on it can also be made of elastic or any other type of stretch material. The garment 20 can also be constructed as a full bodysuit, see FIG. 16C , and the waistband 22 can be omitted altogether.
[0112] The garment 20 can have any type of identifying label sewn onto the back of the waistband 22 . If the garment 20 is “seamless” and has a waistband 22 , it can be knit into the waistband 22 . Identifying information can be heat sealed onto the waistband 22 . The garments 20 and 120 can be any length, “boy cut”, “mid-thigh”, “three-quarter thigh”, “above the knee”, “below the knee”, “Capri”, “flood”, “midi”, “ankle”, or any variation of the length up or down the leg. The garments 20 and 120 can also be manufactured without legs, for example as a “thong”, and any other version thereof, and only contain the unique features of the crotch portion of knit sewn in panel 34 and the crotch portion of “cut and sew” sewn in leg panel 134 .
[0113] To help prevent the garment 20 from riding up the leg, in the knit “seamless” construction, five rows of jersey stitches 44 and five rows of diamond-patterned stitches 46 can be incorporated into the garment 20 but are not mandatory. The type of stitches at the hemline can be changed at the manufacturer's discretion to prevent the garment from riding up or down the leg. The alternating five rows of jersey stitches 44 and five rows of diamond-patterned stitches 46 are not mandatory for the function of the garment. Other types of materials, such as a silicone strip, may also be added to the inside of the hems 48 and 144 to prevent them from riding up at the manufacturers discretion. The “cut and sew” versions of the garment 120 do not contain these stitches. First and second leg opening 50 a and 50 b respectively of hem 50 can have any detailing the manufacture wishes to incorporate into the garment 120 to hold the garment in place such as a strip of silicone. Other types of seam placement such as princess seams on the torso portion of the garment 23 are also at the manufacturer's discretion and will not affect the function of the knit sewn in leg panel 38 or the “cut and sew” sewn in leg panel 138 .
[0114] The shape of the knit sewn in leg panel 38 , that eliminates the need for an inner thigh seam, can be long and rectangular, short and rectangular, hourglass, tapered or not depending on the length of the garment 20 . In a “seamless” version of garment 20 the crotch portion of sewn in panel 24 may be made narrower to form the hourglass shape by increasing the tension on the stitches in the crotch portion of the sewn in panel 24 . On an ankle length version of garment 20 , the hem 50 , can be made narrower. This can be accomplished by increasing the tension in the stitches at the hem 50 . Cutting the lower portion of the inner leg portion of the knit sewn in leg panel from an area from the ankle to above the knee in a tapered fashion out of knit tubular fabric will also accomplish a tapered effect. If the knit sewn in leg panel 38 is knit as a separate piece, and is not cut from a long tubular piece of fabric, the number of stitches may be increased or decreased, as the pattern requires achieving the desired shape. The shape of the knit sewn in leg panel 38 will vary depending on the size and length of the garment 20 but the pattern should always be cut to cover the part of leg and crotch of body 40 to be functional. It can be cut to cover an area larger than the inner part of leg and crotch of body however if the manufacturer wishes.
[0115] Regarding the “cut and sew” sewn in leg panel 138 required for a “cut and sew” garment, once again, the pattern piece is cut in a tapered hourglass shape for an ankle length version of garment 20 . The shape of the sewn in leg panel 138 will vary depending on the size and length of the garment 120 but the pattern should always be cut to cover the part of leg and crotch of body 140 to be functional. It can be cut to cover an area larger than the inner part of leg and crotch of body 140 however if the manufacturer wishes.
Description FIGS. 18 A- 19 E
[0116] Another embodiment of the present invention is incorporated and illustrated in FIGS. 18A-19E . In general, the present invention in FIGS. 18A and 18B is shown generally as a pair of washable pantyhose with plated inner thigh area, plated crotch and plated bottom and sides of foot or garment 220 . It is an improvement over prior pantyhose. A person 228 is wearing the garment 220 and comprises numbers 220 through 250 . For purposes of clarity, like reference numerals are used where appropriate. The garment 220 is comprised of a torso portion 223 having a waistband 222 , with a top of folded over waistband 248 , a seam of folded over waistband 250 , a front portion 224 , and a back portion 226 . Torso center front and back seams, 227 a and 227 b respectively, hold the two torso portions of the pantyhose 223 together. Further, the garment 220 contains a pair of leg portions of the garment 239 that are connected at a perforated line 230 and extend downwardly to the plated bottom and sides of foot 244 of the person 228 wearing the garment 220 . The plated bottom and sides of foot 244 has a toe seam 245 . A plated crotch gusset 236 , which will be further described, in FIG. 19D and FIG. 19E , covers a region of the angle formed by the junction of the legs or crotch 232 . A plated knit inner thigh leg area 242 , of the garment 220 , and a plated crotch gusset 236 , covers an inner part of the leg 240 . Plated inner thigh knit leg area 242 is adjacent to a plated crotch gusset 236 that will be further described in FIG. 19D and FIG. 19E .
[0117] An important aspect of this invention is to provide the garment with the plated knit inner thigh leg area 242 , and plated crotch gusset 236 , which is generally shown in FIGS. 18A , 18 B. Plated knit inner thigh leg area 242 , is knit into garment 220 so as to overlay the inner part of leg 240 of the person 228 . The relative position of plated knit inner thigh leg area 242 , is to cover the inner part of the leg 240 and is comprised of yarns that have stretch, wicking, antibacterial or antimicrobial, and friction reduction properties. This will be further described in FIG. 19B and FIG. 19G . The plated crotch gusset 236 is comprised of fibers that have wicking and antibacterial or antimicrobial characteristics and or friction-reducing properties will be further described in FIG. 19E , and FIG. 19F .
[0118] Tactel®, a type of wicking yarn is used on the inside of the plated area and Tactel®, cotton, polyester, viscose, and or wool, for example, would be utilized on the outside of the plated areas. Or, a yarn or fiber with a higher DPF, denier per filament, is plated on the inside of a fabric, and a yarn or fiber with a lower DPF, is plated on the outside of a surface of a fabric. The higher DPF material has fatter, larger filaments and the lower DPF material has more smaller, thinner filaments. As a result the moisture on the inside of a person's skin is wicked away by the material with the larger DPF to the surface of the fabric with the lower DPF. The surface of the wetted area on exterior surface of the garment is greater than the surface of the wetted area on the inside. The result is that a person's skin stays dry.
[0119] Another method of producing wicking would be to plate fibers or yarns with different shapes together. For example, if moisture is on a person's skin, it will wick from an surface comprised of yarns or fibers that has few “lobes” or “clover leafed” shapes into a surface which is comprised of yarns or fibers that have many “lobes” or “clover leafed” shapes. The surface of the wetted area on exterior surface of the garment is greater than the surface of the wetted area on the inside. The result is that a person's skin stays dry.
[0120] FIG. 18B is a perspective view of garment 220 in FIG. 18A showing the torso portion 223 and leg portions 239 of the garment 220 . The torso portion 223 shows a folded over waistband 222 with a top 248 and a seam 250 . The leg portions 239 have a plated bottom and sides of foot 244 and a toe seam 245 . The front portions of the garment 224 are sewn together at the torso center front seam 227 a and the back portions of garment 226 is sewn together at the torso center back seam 227 b . There is a plated crotch gusset 236 in a region of the angle formed by the junction of the legs or crotch 232 . This will be further explained in FIGS. 19E and 19F . A plated knit inner thigh leg area 242 . in the garment 220 covers the inner portion of the leg 240 . This will be further explained in FIGS. 19B and 19G . The plated bottom and sides of foot 244 and the toe seam 245 complete the garment.
[0121] FIG. 19A is a representation of the circular knit tubes 252 out of which the pantyhose garment 220 is constructed. They are comprised of a circular knit tube tops 246 , tops of the folded over waistband 248 , and waistband seam placement 250 b that form the waistband 222 . The outer sides of knit tubes forming pantyhose garment 254 , and the inner side of knit tubes 256 , comprises the tubes. A portion of the tube is knit in a plated manner and creates a plated knit inner thigh leg area 242 . This plated knit inner thigh leg area 242 . is designed to cover the inner part of leg 240 . A cross section through the plated knit inner thigh leg area 242 and plated bottom and sides of foot 244 is represented by lines 19 b - 19 b and will be further explained in FIGS. 19B and 19G . An area of the bottom of the knit tube is knit in a reinforced manner and forms the plated bottom and sides of foot 244 when the toe seam 245 is stitched.
[0122] FIG. 19B is an enlarged detail of the plated inner thigh sections 19 b - 19 b and plated bottom and sides of foot 19 b - 19 b . An outer “bright” yarn or friction reducing yarn 238 is plated over an inner wicking yarn or fiber 243 . The resulting knit fabric that makes up the plated knit inner thigh leg area 242 and the plated bottom and sides of foot 244 . is worn against the person's 228 skin. The wicking yarn can be chemically treated to be antibacterial, antifungal or bacteriostatic.
[0123] FIG. 19G is an alternative method of constructing the cross section taken through section lines 19 b - 19 b in FIG. 19A . An antibacterial, antifungal or bacteriostatic yarn or fiber 241 is knit together with a wicking yarn or fiber 243 to form the inner layer and plated with an outer “bright” yarn or friction reducing yarn. The resulting knit fabric that makes up the plated knit inner thigh leg area 242 and the plated bottom and sides of foot 244 is worn against the person's 228 skin Should the manufacturer wish the wicking yarns or fibers can be chemically treated to be antibacterial, antifungal or bacteriostatic. In this case the antibacterial, antifungal or bacteriostatic yarn or fiber 241 can be omitted to reduce costs.
[0124] FIG. 19C is identical to FIG. 19A with the exception that the inner side of knit tube forming pantyhose garment with the cut edges of knit tubes, 256 a the front, and 256 b the back, respectively are shown.
[0125] FIG. 19D is a perspective view of the two leg panels that have been sewn together forming the torso center front and back seams, 227 a and 227 b respectively. The toes have been sewn forming the toe seam 245 . All other parts are identical to those previously identified. The plated crotch gusset 236 is shown separately and has not been sewn in and a cross section represented by lines 19 e - 19 e will be further explained in FIG. 19E . To finish the pantyhose garment 220 , a hole is burned into the crotch 232 area of the garment 220 , and then the plated crotch gusset 236 is stitched into the hole. To garment 220 may be “boarded” to obtain a pair of pantyhose in the shape of a person's 228 leg or not, and is at the discretion of the manufacturer.
[0126] FIG. 19E is an enlargement of a cross section taken through section lines 19 e - 19 e in FIG. 19D . An outer antibacterial, antifungal or bacteriostatic yarn or fiber 241 is plated over an inner wicking yarn or fiber 243 . The resulting knit fabric that makes up the platted crotch gusset 236 is worn against the person's 228 skin Should the manufacturer wish the wicking yarns or fibers can be chemically treated to be antibacterial, antifungal or bacteriostatic. In this case the outer antibacterial, antifungal or bacteriostatic yarn or fiber 241 can be omitted to reduce costs.
[0127] FIG. 19F is an alternative method of constructing the cross section taken through section lines 19 e - 19 e in FIG. 19D . An antibacterial, antifungal or bacteriostatic yarn or fiber 241 is knit together with a wicking yarn or fiber 243 to form the inner layer and plated with an outer “bright” yarn or friction reducing yarn. The resulting knit fabric that makes up the platted crotch gusset 236 is worn against the person's 228 skin Should the manufacturer wish the wicking yarns or fibers can be chemically treated to be antibacterial, antifungal or bacteriostatic. In this case the antibacterial, antifungal or bacteriostatic yarn or fiber 241 can be omitted to reduce costs.
Description FIGS. 20 A- 20 D
[0128] Another embodiment of the present invention is incorporated and illustrated in FIGS. 20A-20D . In general, the present invention in FIGS. 20A and 20C is shown generally as a washable below the knee garment with plated inner thigh area or garment 320 . It is an improvement over prior garments. A person 328 is wearing the garment 320 and comprises numbers 320 through 345 . For purposes of clarity, like reference numerals are used where appropriate. The garment 320 is comprised of a torso portion 323 having a waistband 322 , with a top of folded over waistband 325 , a hem of folded over waistband 329 , a front portion 324 , and a back portion 326 . Torso center front and back seams, 327 a and 327 b respectively, hold the two torso portions of the garment 320 together. Further, the garment 320 contains a pair of leg portions of the garment 339 that are connected at a perforated line 330 and extend downwardly. A plated crotch gusset 334 , which will be further described, in FIG. 20C and FIG. 20D , covers a region of the angle formed by the junction of the legs or crotch 332 . An inner part of the leg 340 is covered by a plated knit inner thigh leg area 335 , and a plated crotch gusset 334 . Plated inner thigh knit leg area 336 will be further described in FIG. 20A and FIG. 20B . A hem seam 338 and the bottom of folded edge of hem 340 finish the garment.
[0129] An important aspect of this invention is to provide the garment with the plated knit inner thigh area 336 , a plated crotch gusset 334 , and which is generally shown in FIGS. 20A , 20 B. The garment 320 is constructed in the same way as the pantyhose garment 220 , thus avoiding seams in the inner part of leg 345 . The plated knit inner thigh leg area of garment 336 is knit into garment 320 so as to overlay the inner part of leg 345 of the person 328 . The relative position of plated knit inner thigh leg area of garment 336 is to cover the inner part of leg 345 and is comprised of yarns that have stretch, wicking, antibacterial, antifungal and or antimicrobial, and friction reduction properties. This will be further described in FIG. 20 B. The plated crotch gusset 334 is comprised of fibers that have wicking and antibacterial, antifungal or antimicrobial characteristics and will be further described in FIG. 20C .
[0130] FIG. 20B is an enlarged detail of the plated inner thigh sections 20 b - 20 b . An outer “bright” yarn or friction reducing yarn 344 is plated over an inner wicking yarn or fiber 342 . The resulting knit fabric that makes up the plated knit inner thigh leg area 336 is worn against the person's 328 skin. The wicking yarn can be chemically treated to be antibacterial, antifungal or bacteriostatic. Or, it can be knit with yarns or fibers that are antibacterial, antifungal or bacteriostatic together with the outer “bright” yarn or friction reducing yarn 344 so that the wicking/antibacterial, antifungal, bacteriostatic layer is against the skin 328 and the outer “bright yarn or friction reducing yarn 344 is on the outer surface of the garment.
[0131] FIG. 20C is an enlargement of a cross section taken through section lines 20 c - 20 c of the plated crotch gusset 334 . An outer antibacterial, antifungal or bacteriostatic yarn or fiber 346 is plated over an inner wicking yarn or fiber 342 . The resulting knit fabric that makes up the platted crotch gusset 334 is worn against the person's 328 skin. Should the manufacturer wish the wicking yarns or fibers can be chemically treated to be antibacterial, antifungal or bacteriostatic. In this case the outer antibacterial, antifungal or bacteriostatic yarn or fiber 346 can be omitted to reduce costs. An outer “bright” yarn of friction reducing yarn 344 may or may not be used in place of the outer antimicrobial, antifungal or antibacterial yarns or fibers.
[0132] FIG. 20D is an alternative method of constructing the cross section taken through section lines 20 c - 20 c in FIG. 20D . An antibacterial, antifungal or bacteriostatic yarn or fiber 241 is knit together with an inner wicking yarn or fiber 243 to form the inner layer and plated with an outer “bright” yarn or friction reducing yarn 238 . The resulting knit fabric that makes up the platted crotch gusset 236 is worn against the person's 228 skin Should the manufacturer wish the wicking yarns or fibers can be chemically treated to be antibacterial, antifungal or bacteriostatic. In this case the antibacterial, antifungal or bacteriostatic yarn or fiber 241 can be omitted to reduce costs.
Description FIG. 21 , FIG. 22 , FIG. 23 and FIG. 24
[0133] FIG. 21 , FIG. 22 , FIG. 23 and FIG. 24 represent additional embodiments of garments that have wicking, antibacterial/antifungal/bacteriostatic and low friction properties. These garments have areas of inner wicking yarn 342 and outer “bright” yarn or friction reducing yarn 344 which are represented by the hatch marks. In these examples the inner friction yarn is treated with an antibacterial, antifungal or bacteriostatic chemicals. Antibacterial, antifungal or bacteriostatic fibers can also be incorporated with the inner wicking yarn 342 when plating the material.
[0134] The plating of these yarns in areas where there is moisture, heat and friction of skin rubbing against skin is very important in the reduction of Intertrigo for the wearer of the garments. Affected areas can include areas between and below the breasts as in FIG. 21 , below the abdomen, between the ribs and under the gut as in FIG. 22 , below the gut, in the crotch, and between the thighs as in FIG. 23 , and under the armholes and around the neck as in FIG. 24 . All of these treated areas may be included singularly or in addition to other treated areas of a garment. All of these treated areas, represented by the hatch marks, can have the areas of inner wicking yarn 342 , antibacterial/antifungal/bacteriostatic yarns 346 , that are plated with an outer “bright” yarn or friction reducing yarn 344 . The manufacturer is not limited to plating the designated areas exclusively. The garments may be plated in their entirety. The area with the hatch marks should consist of an inner wicking yarn 342 layer and an outer “bright” yarn or friction reducing yarn 344 . The antimicrobial, antifungal or antibacterial yarns or fibers can be knit with the inner wicking yarn 342 or the inner wicking yarn 342 can be chemically treated with antimicrobial, antifungal or antibacterial chemicals. The method to make these garments can either be “cut and sew”, utilizing either wovens or knits, or knit, using circular or flat knitting techniques. The knits may be constructed with seams in a “cut and sew” fashion or knit in a circular method to produce “seamless” knit garments.
[0135] It is understood that the invention is not limited to human apparel. The invention can also be used in pet apparel, and the like.
[0136] It is also understood that the invention is not restricted to the detailed description of the invention, which may be modified without departure from the accompanying claims.
SUMMARY, RAMIFICATIONS, AND SCOPE
[0137] From the description above, a number of advantages of my knit plated areas become evident:
[0138] (a) The portions of the panel from below the knee or above the knee to the crotch, i.e., the upper portion of the leg panels from above the knee to the crotch area, 36 b , 136 b , and the plated knit inner thigh leg area 242 eliminates the need for an inner thigh seam and thus irritation for the wearer, and consists of wicking fibers that have a plated outer friction reducing yarn or fiber, wick moisture away from a person's skin and reduce friction between a person's legs.
[0139] (b) The wicking. The combination of these yarns helps the skin stay dry, and help reduce the possibility of infections and concomitant odors. Or, the wicking yarns or fibers are plated with an antibacterial, antifungal, and bacteriostatic yarns or fibers on the inside of the garment and the friction reducing yarns or fibers are plated on the outside of the garment.
[0140] (c) Should the manufacturer wish, the antibacterial, antifungal, and bacteriostatic yarns or fibers can be eliminated in all of the areas previously described examples and the wicking fibers can be treated chemically with antibacterial, antifungal, and bacteriostatic chemicals to help eliminate odors and infections.
[0141] (d) Should the manufacturer wish the friction reducing yarns on the knit sewn in leg panel could be eliminated on one side to reduce costs. Friction reducing yarns are very expensive when compared to other yarn costs, sometimes ten times as much. The function of the friction reduction is not reduced for the wearer of the garment when one side is plated. Since friction reducing yarns typically retain heat it is preferable that they be eliminated on one side.
[0142] (e) The panels and gussets, whether knit sewn in leg panel 38 , the “cut and sew” leg panel 138 , and the plated crotch gusset 236 with the plated knit inner thigh panel 242 , or any other type of panel with the previously described construction can be sewn or plated into any type of garment including ones not mentioned here with the sole purpose of reducing moisture, friction and bacteria or fungus or yeast for the wearer. It is up to the manufacturer to choose the type of garment to sew or plate the panels into.
[0143] (f) The panels or plated areas can be utilized by both genders and are not age specific. They can be utilized in the manufacture of any type of articles of apparel where wicking, friction reduction, and antibacterial, antifungal, and bacteriostatic properties are needed.
[0144] (g) The panel or plated areas' shapes can be tailored to accommodate the various types of garments manufactured and can be made larger or smaller as size determines as long as the affected areas are covered.
[0145] (h) The panels or plated areas can be used independently of a wicking and antimicrobial and bacteriostatic gusset should the manufacturer wish.
[0146] (i) All comparable parts of the garments are interchangeable, For example, the knit sewn in leg panel 38 can be utilized on a “cut and sew” garment and the “cut and sew” leg panel 138 can be utilized in a seamless garment should the manufacturer wish.
[0147] (j) The knit plated panels and areas in the legwear or hosiery can be used on any type of hosiery or legwear whether it is sheer, semi-opaque, opaque, non-control, control, a shaper, or any other type. It may also be utilized with any type of pattern such as lace, geometric, stripes, dots, or any other one the manufacturer wishes to utilize.
[0148] (k) The combination of the yarns helps the skin stay dry and without irritation from rubbing. Intertrigo is a red, moist irritation or friction in the following areas of a person; the groin and inner thigh area of people whose thighs rub together, between and under the breasts, between the ribs, under the gut, under the arm, in skin folds between the ribs and around the neck. The moist irritated skin can be infected with yeast, fungus and bacteria. The antibacterial, antifungal, and bacteriostatic yarns or chemical treatment of the fibers helps reduce infection. These types of embodiments of the wicking, friction reduction and antibacterial, antifungal, and bacteriostatic yarn or chemicals, reduce Intertrigo for the wearers.
[0149] (l) The garments contain panels or plated areas that are knit, thus providing superior fit over a woven garment with plated panels or areas. Knit conform more to the body and move with it when compared to a woven garment with plated areas or panels. Knitting is a very different process than weaving and is preferred for a garment that fits closely to the body that is curved.
[0150] (m) Two criteria for ensuring wicking are utilized that will ensure that the skin stays dry. The first method included yarns or fibers with a higher DPF, denier per filament, is plated on the inside of a fabric, and a yarn or fiber with a lower DPF, is plated on the outside of a surface of a fabric. The second method of using fibers or yarns with different shapes where there are fewer shapes on the yarns or fibers next to the skin in comparison to the number of shapes on the yarns or fibers on the outside surface of the material. Both methods insure that the surface of the wetted area on exterior surface of the garment is greater than the surface of the wetted area on the inside. The result is that a person's skin stays dry.
[0151] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the gusset can have other shapes such as oval, trapezoidal, triangular, etc. The inner leg panels or plated areas can have other shapes, such as oval, trapezoidal, etc as long as the inner thigh area is covered.
[0152] The seams can be flat locked, French seamed; simulated French seamed, double-stitched, flat-felled, hairline, double-stitched, over edge-stitched, topstitched, double topstitched, lapped, tucked, etc. The style lines for the seam placement in the “cut and sew” garment's “cut and sew” sewn in leg panel can be placed either above the knee or below it in any area to the ankle and can be horizontal or oblique. All parts of the garment including the inner leg panels, crotch areas, and gussets may contain a stretch fiber for memory and shape retention. An illustrative example of the spandex type of yarn may take the form of DuPont's® Lycra® brand spandex or Bayer's® and Dorlastan®. The spandex fiber can be covered, wrapped, with other fibers—natural or man-made—and is often used in this form in hosiery, narrow fabrics and wovens for ready-to-wear. The spandex can be covered in five ways: single-covered, double-covered, corespun, interlaced or air-covered and core-twisted as the manufacturer wishes. The knits can be warp knits, such as a Raschel knit, or a Tricot knit, and is ideal but not limited to bodywear and active sportswear. Circular knits, such as jersey knits, are ideal for bodywear, sportswear, and hosiery. In hosiery and ready to wear, where circular knitting machines are utilized such as a Santoni® machines, the spandex can also be “laid in” between rows of knitting, or knitted into every stitch, the latter producing superb fit and uniformity in the stitches.
[0153] The amount of spandex can range from as little as 1% to as much as 30% for shapewear. The bodies of the garments may be made of many materials whether man-made or natural or any and all blends of man-made fibers and synthetics. They include cotton, wool, silk, leather, linen, vinyl, Model, nylon-polyamides and polyamide co-polymers, LYCRA® spandex in different filament configurations, orlon, polyvinylidene fluoride, such as KNAR® polyester, for example, polyethylene terepthalate, glycol modified polyesters, such as PETG®, KODURA®, rayon, orlon cellulosic fiber blends, and the like, as well as blends of the above. The choice of materials to make the bodies of the garment out of is left to the discretion of the manufacturer. Closures may be zippers, Velcro®, buttons, snaps or any other type of closure the manufacturer wishes to utilize. The fly closure may be made in any design as the manufacturer wishes.
[0154] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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Articles of clothing that incorporate fabrics or chemicals having wicking, antibacterial/antifungal and low coefficients of friction either overall or in specific areas of the apparel that will minimize the development of irritation, bacterial and fungal infections of the skin. The invention also includes methods for producing this wicking, antibacterial/antifungal and low coefficient of friction apparel.
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This is a continuation of application Ser. No. 07/456,205, filed Dec. 20, 1989, now abandoned, which is a continuation of application Ser. No. 07/278,864 filed Dec. 2, 1988, now abandoned, which is a divisional of application Ser. No. 07/154,255, filed Feb. 10, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of and an apparatus for shaping a film cartridge for accommodating therein a roll film, and more particularly to a method of bending a shell plate into a hollow cylinder, capping the hollow cylinder and clinching the assembly thus obtained, and to an apparatus for carrying out the method.
2. Description of the Prior Art
There have been put into practice various methods of and apparatuses for bending a shell plate into a hollow cylinder, mounting caps on the upper and lower ends of the hollow cylinder (capping), and clinching the assembly thus obtained in shaping of a film cartridge. For example, in Japanese Unexamined Patent Publication No. 59(1984)-143841, there is disclosed an improvement on such an apparatus and a method.
Conventionally, there has been encountered a problem in shaping of the film cartridge that when a mandrel having a perfectly circular cross section is used for bending the shell plate, the cross section of the obtained shell does not become perfectly circular due to the spring back effect of the shell plate. Accordingly, a mandrel having an ellipsoidal cross section has been generally used. However, the ellipsoidal mandrel is disadvantageous in that since the cap, which is perfectly circular in shape, cannot be mounted on the shell plate as the shell plate is bent around the ellipsoidal mandrel, the shaped shell plate must be removed from the mandrel and the removed shell plate having an Ω-shaped cross section must be conveyed to and positioned at the capping station. Due to its cross-sectional shape, the Ω-shaped shell plate is difficult to convey and position. Further, the Ω-shaped shell plates are apt to fluctuate in size and shape, and accordingly, it is very difficult to cap the Ω-shaped shell plates with high accuracy. Further, since capping and clinching must be effected at a station different from the station at which the shell plate is bent, the apparatus is enlarged in size and complicated in structure.
SUMMARY OF THE INVENTION
In view of the foregoing observations and description, the primary object of the present invention is to provide a method of and apparatus for shaping a film cartridge in which a film cartridge having a perfectly circular cross section can be obtained by use of a mandrel having a perfectly circular cross section when bending a shell plate.
Another object of the present invention is to provide a method of and an apparatus for shaping a film cartridge in which bending of the shell plate, capping and clinching can be accomplished at a single station.
In one aspect of the present invention, there is provided a method of shaping a film cartridge having a hollow cylindrical shell and caps mounted on ends of the shell, comprising the steps of bringing a shell plate into abutment with a mandrel having a perfectly circular cross section, bending the shell plate around the mandrel by a bending roller, mounting a cap on an end of the shaped shell plate while it is on the mandrel, and clinching the cap to the shell plate while the cap and the hollow shell are grasped from the outside.
In another aspect of the present invention, there is provided an apparatus for shaping a film cartridge having a hollow cylindrical shell and caps mounted on ends of the shell, comprising a mandrel having a perfectly circular cross section, an auxiliary fitment for pressing a shell plate against the mandrel, a shaping device which has a bending roller and is movable toward the mandrel to shape the shell plate around the mandrel, and a capping-and-clinching device which is movable toward the mandrel to mount the cap on the cylindrical shell plate on the mandrel and clinches the cap to the shell plate while grasping the hollow cylindrical shell and the cap from the outside.
In accordance with the present invention, the shell plate is bent around the mandrel into a hollow cylinder having a perfectly circular cross section, and the cap is clinched to the shell plate while it is on the mandrel. That is, shaping of the shell plate, capping and clinching are accomplished at one station.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a film cartridge shaping apparatus in accordance with an embodiment of the present invention,
FIG. 2 is a side view showing the shaping device employed in the apparatus,
FIG. 3 is an enlarged fragmentary view showing a part of the capping-and-clinching device employed in the apparatus,
FIG. 4 is a front view showing the shaping device in the bending operation,
FIG. 5 is a fragmentary side view of the shaping device in the bending operation, and
FIG. 6 is a fragmentary front view of the apparatus in the capping and clinching operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2, a mandrel 1 which is perfectly circular in cross section and an auxiliary fitment 2 are conveyed left and right as seen in FIG. 1 by a driving device (not shown). The auxiliary fitment 2 is swung by a lever (not shown) about a pin 3 away from and toward the mandrel 1 to pinch a shell plate 50 therebetween. The mandrel 1 together with the auxiliary fitment 2 will be referred to as the "mandrel assembly", hereinbelow.
A shaping device is provided below the mandrel assembly. The shaping device includes a pair of arms 6 mounted on a roller holder 8 for pivotal motion about pivots 7 fixed to the roller holder 8. A bending roller 4 is mounted on the upper end portion of each of the arms 6 for rotation about a shaft 5, and an auxiliary fitment 6a is mounted on an intermediate portion of each of the arms 6. The arms 6 are arranged so that the bending rollers 4 are opposed to each other, and each arm 6 is supported by a roller pusher assembly 11 disposed on the outer side of the arm 6 opposite to the roller 4. The roller pusher assembly 11 includes a roller pusher 19 which is slidably received in a hole and is urged by a compression spring 13 to project from the hole and to abut against the outer side of the arm 6. The shaping device having the structure described above is integrally moved up and down by cams (not shown) which are provided in housings 9 and are associated with shafts 12 fixed to the lower surface of the roller holder 8. FIG. 2 shows a condition in which the shaping device is in the lower position, and FIG. 5 shows a condition in which the shaping device is in the upper position in which the shell plate 50 is shaped up by the bending rollers 4 and pressed against the peripheral surface of the mandrel 1. Since the shaping device moves solely in a vertical direction by means of shaft 12 in FIGS. 2 and 4, as described above, the mandrel 1 must remain stationary relative to the moving bending roller during the shaping of the shell plate.
A capping-and-clinching device are provided on one side of the mandrel assembly and the shaping device so as to be movable in parallel to the longitudinal axis of the mandrel 1. The capping-and-clinching device includes a chuck 14 (FIG. 3) comprising a pair of chuck halves 15 supported for rotation about a common pivot 18 fixed to a chuck holder 20. A pair of drive rods 16 are rotatably connected to the respective chuck halves 15 by way of pivots 17. The drive rods 16 are driven by a cam (not shown) to open and close the chuck 14 to grip a portion of the cylindrical shell plate 50 to be capped. A cap chute 10 for supplying caps 40 is provided above the chuck holder 20. The cap 40 has a central opening 40a through which a film spool projects outside, and an annular groove 40b extending along the peripheral edge of the cap 40 and opening on one side of the cap 40. On the other side of the cap 40 is formed an annular recess surrounded by an annular wall 40c which defines the inner peripheral wall of said annular groove 40b. The chuck holder 20 is moved back and forth in parallel to the longitudinal axis of the mandrel 1 by a shaft 25 slidably supported on a holder 26. A clinching head 22 is moved back and forth in parallel to the longitudinal axis of the mandrel 1 by a shaft 23 which is slidably supported on the holder 26. The clinching head 22 brings the cap 40 into engagement with an end of the cylindrical shell plate 50 so that the end of the shell plate 50 is received in the annular groove 40b of the cap 40. The clinching head 22 has expansion claws 22a which can be expanded by a shaft 24 slidably supported in the shaft 23 and a cam (not shown) associated with the shaft 23 to radially outwardly press the annular wall 40c of the cap 40. Since the clinching head 22 moves solely in a direction parallel to the longitudinal axis of the mandrel 1 by means of shaft 23 in FIGS. 1 and 6, as described above, the mandrel 1 must remain stationary relative to the moving capping-and-clinching device during the capping of the shell plate.
Now the operation of this apparatus will be described.
First the auxiliary fitment 2 is swung away from the mandrel 1 and a shell plate 50 for forming the shell portion of the film cartridge is inserted between the auxiliary fitment 2 and the mandrel 1. Thereafter the auxiliary fitment 2 is swung toward the mandrel 1 to pinch therebetween the shell plate 50. In this state, the mandrel 1 is moved to the position shown in FIGS. 1 and 2.
Thereafter, the shaping device is moved from the position shown in FIG. 2 to the position shown in FIG. 4, whereby the shell plate 50 is shaped into a hollow cylinder having a substantially perfect circular cross section as shown in FIG. 5 by the pair of bending rollers 4 rolling on the mandrel 1 with the shell plate 50 sandwiched therebetween.
Then, the chuck 14 is opened, that is, the chuck halves 15 are swung away from each other, and is moved toward the mandrel 1 together with the chuck holder 20 to a capping position. In response to the movement of the chuck 14, the clinching head 22 is moved toward the mandrel 1. When the chuck 14 reaches the capping position and the end portion of the shell plate 50 is inserted between the pair of chuck halves 15, the chuck 14 is closed. The chuck halves 15 are respectively provided with semicircular recesses which define a circular opening when the chuck 14 is closed as can be understood from FIG. 3. After the chuck 14 is closed, the clinching head 22 is moved toward the shell plate 50 to bring the cap 40 into engagement with the end portion of the shell plate 50. This condition is shown in FIG. 6. Then the shaft 24 is driven to expand the expansion claws 22a to radially outwardly press the annular wall 40c of the cap 40 against the end portion of the cylindrical shell plate 50. This is accomplished with the shell plate 50 and the cap 40 grasped by the chuck 14, whereby the cap 40 is clinched to the shell plate 50.
Thereafter, the expansion claws 22 are closed and the clinching head 22 is returned to the position shown in FIG. 1. Further, the chuck 14 is opened and the chuck holder 20 is returned to the position shown in FIG. 1. Then the shaping device is moved downward to the position shown in FIG. 2, and the mandrel assembly is moved to the next station carrying thereon the capped hollow cartridge.
Though, in the above embodiment, a pair of bending rollers and a single auxiliary fitment are used, a plurality of pairs of bending rollers and a plurality of auxiliary fitments may be used. The shaping device or the capping-and-clinching device may be separately used.
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When shaping a film cartridge having a hollow cylindrical shell and caps mounted on ends of the shell, a shell plate is brought into abutment with a mandrel having a perfectly circular cross section and bent around the mandrel by a bending roller. A cap is mounted on an end of the hollow cylindrical shell while it is on the mandrel, and the cap is clinched to the hollow shell while the cap and the hollow shell are grasped from the outside.
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OBJECT OF THE INVENTION
[0001] The invention refers to a procedure for manufacturing at ambient temperature lignin micro and nanofibres from lignin and other resinous compounds without adding polymers (binders) which imply considerable expense for the spinning process. The aim of the invention is the manufacture of carbon fibres using a heat treatment of the lignin fibres obtained by means of the procedure herein described. There are two types of commercial carbon fibres which, as is well known, are of great importance for industry and technology due to their chemical, electrical, magnetic and mechanical properties. These are: the so-called high performance fibres characterised by excellent mechanical performance (aerospace industry and others) and general purpose fibres, characterised by their high specific surface values (activated carbon, substrata for catalytic applications, gas storage, absorption, etc.). The procedure claimed herein is aimed at the manufacture of the latter. Likewise an object of the present invention is the device claimed herein for the manufacture at ambient temperature of lignin micro and nanofibres, using the co-electrospinning technique.
[0002] With regard to their structure, once treated thermally, they give rise to so-called general purpose carbon fibres and the fibres obtained can be single or hollow, although they can also be of the coaxial type, in which the lignin material coaxially coats another different material which can either be of the polymer or ceramic type. The fibres can likewise be doped with catalytic particles, or incorporate other materials whose purpose is to modify the end structure and the properties of the carbon fibres obtained from the lignin fibres.
[0003] Before obtaining the lignin fibres, the lignin must be prepared in solution form so that it can be spun at room temperature. This is done by means of the procedure claimed herein. Subsequently, to obtain the micro and nanometre-sized fibres, the lignin solution must be forced through the device illustrated in FIG. 1 . a ., likewise the object of the invention, which, by means of electrohydrodynamic and surface tension forces, is capable of generating a jet of two liquids which flow coaxially, so that the lignin solution is surrounded by another, easily evaporable, liquid whose purpose is to delay the evaporation of the lignin solvent, which would result in the solidification of the latter before the fibres are able to form. Once the liquid that flows on the outside has evaporated, the solvent present in the lignin solution starts to evaporate and quickly leads to the solidification of the lignin flow which gives rise to the lignin fibres.
[0004] When you wish to manufacture hollow or coaxial fibres (lignin coating a different material), you will need to form a triple coaxial jet (made up of three liquids) by using the device in FIG. 1 . B, so that the lignin solution flows between an inner liquid, which it surrounds, and the other outer liquid, the evaporable liquid, which surrounds it. Depending on its nature, the innermost liquid may serve different purposes. For example, if this liquid is inert (in the sense that it fails to solidify during the fibre formation process) hollow nanofibres are obtained once the inert liquid spontaneously leaves the inside of the fibres (or it is removed by means of an appropriate process). On the contrary, if the liquid which flows through the inside is liable to solidify in a time similar to the time it takes for the lignin to solidify, coaxial fibres are obtained in which the inner material is surrounded by a layer of lignin.
STATE OF THE ART
[0005] The carbon fibres are of extraordinary importance due to their wide variety of applications in the field of materials engineering. Among them, worthy of particular mention is their use in catalysis, in adsorption and absorption beds, in fuel cell electrodes, in gas storage, nanoelectronics and compound materials, in separation processes and any other application requiring materials with a very high specific surface area.
[0006] The process for manufacturing carbon fibres requires the spinning of precursor fibres which are transformed into carbon fibres following the appropriate heat treatment.
[0007] The spinning of the precursor fibres requires their extrusion in the liquid state which, to date, has been carried out by means of precursor temperature melting; this process is known as melt-extrusion or melt-spinning. Once the precursor fibres have been manufactured, they are subjected to a heat treatment to stabilise and subsequently carbonise them in order to ultimately produce carbon fibres. The minimum diameter of these carbon fibres is typically approximately 10 mm. Nowadays, fossil fuel precursors are most often used (E. Mora, C. Blanco, V. Prada, R. Santamaría, M. Granda, R. Menéndez, Carbon 2002, 40, 2719-2725; P. J. Walsh, ASM Handbook 2001, vol. 21, Composites) due, in the main, to their low cost compared with that of other polymer-type precursors, such as polyacrylonitrile (PAN), which is the precursor most often used to produce carbon fibres (P. J. Goodhew, A. J. Clarke, J. E. Bailey, Material Science & Engineering 1975, 17, 3-30). It is worth mentioning that, unlike what occurs with many precursors, the PAN can be spun into fibres at ambient temperature, and does not require the use of melt-spinning Recently, other renewable sources or recycled materials have been considered as possible precursors for the manufacture of carbon fibres (W. M. Qiao, M. Huda, Y. Song, S.-H Yoon, Y. Korai, I. Mochida, Energy & Fuels 2005, 19, 2576-2582).
[0008] A low cost precursor for the production of general purpose carbon fibres is lignin. Lignin is the second most abundant polymer in nature after cellulose. This heterogeneous and aromatic bio-macromolecule (phenolic) of natural origin is found on cell walls in plants, and is an underused type of waste from the paper industry (J. H. Lora, W. G. Glassner, Journal of Polymers and the Environment 2002, 10, Nos. 1/2 April). Although, in principle, lignin itself cannot be spun in order to obtain fibres, Kubo and collaborators (S. Kubo, Y. Uraki and Y. Sano, Carbon 1998, 36, No. 7-8, pp. 1119-1124) have reported the use of lignin as a precursor for carbon fibres. In order to obtain lignin fibres, these authors proposed the conversion of lignin into functional polymers by means of an appropriate method for separating timber. The fibres obtained by melt extrusion of the precursor can be subsequently carbonised, following heat stabilisation, in order to obtain carbon fibres. Unfortunately, though the price of lignin is practically nil, the conversion process of lignin into a spinnable material is costly.
[0009] Other groups have recently reported the use of mixtures of lignin with other polymers (binders) which are capable of producing fibres by heat extrusion; the latter can be carbonised following the appropriate stabilisation in order to produce carbon fibres (S. Kubo and J. F. Kadla, Macromolecules 2004, 37, 6904-6911, J. F. Kadia, S. Kubo, R. A. Venditti, R. D. Gilbert, A. L. Compere, W. Griffith, Carbon 2002, 40 2913-2920, S. Kubo, J. F. Kadla, Journal of Polymers and the Environment 2005, 13, No. 2 April, J. F. Kadla, S. Kubo, Composites: Part A 2004, 35 395-400). The diameter of these carbon fibres varies between 30 and 80 microns and, due to the limitations of the melt extrusion process (blocking of the nozzles), it is difficult to reduce the diameter of the fibres to below the indicated values. Here too, the cost of the process rises considerably due to the high cost of the polymers used in the mixtures.
[0010] As mentioned above, polyacrylonitrile (PAN) is likewise used as a precursor to produce fibres at ambient temperature using the electrospinning technique (I. Chun, D. H. Reneker, H. Fong, X. Fang, J. Deitzel, N. C. B. Tan, K. Kearns, J. of Adv. Materials 1999, 31, 36; S. Y. Gu, J. Ren, Q. L. Wu, Synthetic Metals 2005, 155, 157-161). Following the appropriate stabilisation and subsequent carbonisation, carbon fibres are obtained. However, the high cost of the precursor polymer limits the generalised use of this process.
[0011] Finding a procedure which would allow the spinning at ambient temperature of lignin and other highly contaminating organic waste for its transformation into high added-value carbon micro and nanofibres would be of enormous interest due to the environmental benefits and due to the reduction in the cost of the nanofibres manufacturing process.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention claims a simple method for spinning at ambient temperature, and without the addition of polymers, carbon fibre precursors such as lignin, tar and other derivatives of the pyrolis of natural organic waste, and resins of natural origin.
[0013] In order to transform these precursors, e.g. lignin, into substances that can be spun, a lignin mass is poured into an appropriate volume of solvent, such as ethanol, previously heated to temperatures below boiling point as, in general, it is not possible to obtain a viscous solution of lignin by direct dissolution at ambient temperature. The solvent is stirred while the mass is being poured; the proportion of precursor to solvent, for example, lignin to ethanol, can vary between 10% and 90% in mass. The dissolution thus obtained is heated at constant volume, and long enough to dissolve possible precursor agglomerates existing in the mixture. Once the process has terminated, the dissolution is left to cool, at constant volume, to ambient temperature. The range of the viscosity of the solution can vary greatly depending on the final concentration of lignin in ethanol. The concentration of lignin should be the appropriate one for the dissolution to be spun. In general, the concentrations of the precursor in the dissolution must be high enough to obtain the molecular interlinking necessary to be able to obtain the fibres, but their value depends on the morphology and size of the macromolecules making up the precursor used (S. L. Shenoy, W. D. Bates, H. L. Frisch and G. E. Wnek, Polymer, 46, Issue 10 (2005) 3372-3384).
[0014] To be precise, in order to prepare a lignin solution suitable for making lignin nanofibres and nanotubes from Alcell lignin, at ambient temperature, the latter is dissolved in ethanol previously heated to a temperature of approximately 80□C. An Alcell lignin mass equivalent to 40-50% of an initial ethanol mass is poured into the same; the dissolution is stirred constantly during the pouring process. Once the specified quantity of lignin has been poured, the recipient is hermetically sealed and heated to 120□C for 10 minutes with an aim to dissolving any possible lignin agglomerates. Subsequently the solution is left to cool to ambient temperature.
[0015] As has already been mentioned, this process can be used for all kinds of resins of vegetable origin and derivatives of the pyrolysis of natural organic waste in order to obtain fibres of these compounds at ambient temperatures, by simply adapting the rheology of the dissolution (W. M. Qiao, M. Huda, Y. Song, S. H. Yoon, Y. Korai, I. Mochida, Energy & Fuels, 2005, 19, 2576-2582; C. Yoshida, K. Okabe, T. Yao, N. Shiraishi, A. Oya, Journal of Materials Science 2005, 40, 335-339).
[0016] Another claim of this invention is the use of the method described in PCT-027111878.5 for the electrohydrodynamic spinning of the dissolutions prepared according to the procedure described in the present invention. In order to obtain the lignin nanofibres according to method PCT-027111878.5, two capillary needles are placed coaxially as illustrated in FIG. 1 . a . A dissolution of lignin in ethanol prepared according to the method claimed herein is made to flow along the inner needle. When the appropriate electrical field is applied, the meniscus that appears at the top of the inner capillary has a conical shape, the Taylor cone, and a tin jet emanates from its tip, subsequently evolving into the nanofibres.
[0017] However, due to the large concentration of precursor in the dissolution, it was observed that a minimum evaporation of the solvent leads to the solidification of the conical meniscus, which prevents the electrospinning operation. In order to avoid the solidification of the Taylor cone, claimed herein is the use of a solvent flow, typically ethanol, flowing through the annular space between the two needles: a layer of solvent is thus formed and surrounds the Taylor cone formed by the lignin dissolution and the jet emanating from its tip, thus forming a coaxial jet made up of the lignin dissolution and the ethanol surrounding it. The ethanol layer gradually evaporates while the coaxial jet flows downwards, with the result that, once the ethanol layer has disappeared, the evaporation of the solvent leads to the solidification of the lignin and the formation of fibres of this material which are collected in the earth electrode. For the case of lignin, and depending on the ambient conditions and the concentration of lignin in the dissolution, the ethanol flow between the two needles oscillates between 1% and 50% of the flow of the lignin dissolution.
[0018] The viscosity of the dissolution can vary over a wide range of values depending on the concentration of lignin in the dissolution and, consequently, its behaviour as a result of the action of the electrohydrodynamic forces can differ greatly. For example, when the concentration of lignin in ethanol is typically lower than 40%, the dissolution breaks up into an electrospray, with the result that the coaxial jet breaks up into droplets, due to varicose instabilities, before forming fibres and substantially spherical lignin micro or nanoparticles are obtained with micrometric or submicron diameters. For larger concentrations (greater viscosity), the stability of the jet with respect to varicose perturbations increases, and fibres with micro and nanometric diameters are obtained; the diameter of the fibres increases with the concentration of lignin. The formation process of lignin fibres is interrupted and it is not possible to obtain fibres in the stationary state when the viscosity of the dissolution is so high that the electrohydrodynamic forces are incapable of deforming the meniscus and forming the jet; this maximum value of lignin concentration depends to a slight degree on the ambient conditions and their typical value is around 60%.
[0019] Apart from ethanol, other simple organic compounds or mixtures of the same can be used to dissolve the lignin in order to adjust the viscose properties and the volatility of the solution. The preparation process of solutions already described can use any other type of lignin extracted with organic solvents (Organosolv lignins) as a precursor, these same solvents being used to return the lignin to its viscose state. Other resins of vegetable origin can be adapted using an organic solvent for its processing into fibres by electrospinning according to the procedure described (W. M. Qiao, M. Huda, Y. Song, S.-H. Yoon, Y. Korai and I. Mochida, Energy & Fuels, 19, (2005) 2576-2582). Resinous waste obtained from the processing of organic material can be used in the same way as the lignin, by adapting its rheology using physicochemical processes. For example, by means of the liquefaction of biomass (C. Yoshida, K. Okabe, T. Yao, N. Shirashi, A. Oya, Journal of Materials Science 40, (2005), 335-339), resins with a high molecular weight suitable for electrospinning can be obtained.
[0020] The procedure described in PCT-027111878.5 can, likewise, be used with precursor dissolutions claimed herein in order to generate hollow lignin nanofibres from lignin or other resinous compounds. In this case, an injector like the one described in FIG. 1 . b . consisting of three capillary needles placed concentrically needs to be used. An inert liquid which does not change stages during the process is injected through the innermost needle and acts as a mould for the manufacture of hollow nanofibres. The dissolution with the precursor flows through the space between the two innermost needles and the application of an appropriate electrical field gives rise to the formation of a conical meniscus, the Taylor cone, which contains the meniscus of the inert liquid in its interior. To avoid the solidification of the Taylor cone, the solvent is injected through the outermost conduit resulting in an electrified meniscus with a structure in which the meniscus of the dissolution surrounds another internal (inert) one and is in turn surrounded by another which prevents its evaporation. The tips of the three menisci issue jets which, further on, form an electrified coaxial jet where the dissolution of the precursor flows between the solvent and the mould-liquid (inert). Once the solvent layer evaporates, the dissolution of the precursor solidifies, thus forming fibres with a central nucleus of the inert liquid which is gathered in the collector electrode; following the spontaneous exit of the inert liquid from the interior of the fibre, the fibres are transformed into hollow fibres or tubes. Finally, following the appropriate heat treatment, the precursor fibres or tubes are transformed respectively into carbon fibres or tubes.
[0021] If a material liable to solidifying during the process (polymers, sol-gel, etc.) flows through the innermost conduit of FIG. 1 . b ., instead of an inert liquid, the resulting product would be coaxial fibres in which a lignin fibre (or a fibre of the precursor used) contains another fibre made of polymer or another ceramic material in its interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 a . The concentric needles are exposed to an electrical field, facing a polarity electrode opposite that of the needles. At the end of needle 1 , with Q 1 flow, the liquid meniscus of the lignin solution is coated with the ethanol injected by needle 2 , with Q 2 flow. At this point, the electrical voltage established between needle 2 and the collector electrode increases through a high voltage source until both menisci start to deform into the almost conical shape. When the voltage is high enough, a thin jet emanates from the tip of the cone formed by the lignin flow which will be collected in the opposite electrode in the shape of a micro-nanofibre.
[0023] FIG. 1 b . It illustrates a device made up of three concentric needles for the preparation of hollow or coaxial lignin nanofibres. At the end of needle 2 , with Q 2 flow, the liquid meniscus of the lignin solution is coated with the ethanol injected by needle 3 , with Q 3 flow. Q 1 flow of liquid which is lignin immiscible or only slightly miscible with lignin is injected through needle 1 . At this point, the electrical voltage established between needle 3 and the collector electrode increases through a high voltage source until the three menisci start to deform into an almost conical shape. When the voltage is high enough, a thin coaxial jet of lignin solution surrounding fluid 1 emanates from the tip of the coaxial cone made up of the lignin fluid which surrounds the meniscus of fluid 1 , and will be collected in the opposite electrode in the shape of a coaxial micro-nanofibre. If fluid 1 does not solidify during the time of flight, then the fibres collected will be lignin coaxial fibres surrounding the solidified fluid 1 .
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The invention relates to a method enabling the ambient-temperature spinning of ligning originating from Alcell- and Organosolv-type extraction processes. The invention also relates to a method and device for the ambient-temperature production of lignin fibres of micro- and nanometric diameter, by means of electrospinning and co-electrospinning. The resulting fibres can be single strand (electrospinning) and hollow or coaxial (co-electrospinning) fibres. The lignin fibres are transformed into carbon nanofibres after a suitable heat treatment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cellulosic fibrous webs having improved wet and dry strength properties, said webs having been treated with cationic polygalactomannan compositions and an amic acid copolymer.
2. Description of the Prior Art
U.S. Pat. No. 4,391,878 teaches that water soluble copolymers containing the half acid, half amide structure of amic acids can be used to increase the wet strength of paper. Said patent discloses at Column 3 lines 19-33 a means for imparting cationic character to the copolymer which makes it attractive to anionic cellulose fibers for deposition in the wet end of a paper machine.
It is known in the paper making art that negatively charged (anionic) materials can be attached to the negatively charged cellulosic fibers of paper through the use of positively charged (cationic) materials which attach themselves to the negatively charged cellulosic fibers by electrical attraction and either simultaneously or subsequently attach or attract the anionic material on the cellulosic fibrous structure. See, for example, U.S. Pat. No. 3,067,088 granted Dec. 4, 1962 to Hofreiter et al. It is the object of the present invention to provide a material for fixing the wet strength resins of U.S. Pat. No. 4,391,878 to cellulosic fibers, thereby avoiding the necessity of modifying such resins so as to impart to them a cationic character.
SUMMARY OF THE INVENTION
In accordance with the present invention, the amic acid copolymers of U.S. Pat. No. 4,391,878, incorporated herein by reference, are made to appear substantive to cellulose through the use of cationic polygalactomannan gums. The polygalactomannans are generally described in columns 1 and 2 of U.S. Pat. No. 4,301,307 granted June 21, 1977 to DeMartino et al. and assigned to Celanese Corporation also incorporated herein by reference. More particularly, the cationic polygalactomannon compositions for use in the present invention may be described as quaternary ammonium ethers of polygalactomannan gum. Preferred are quarternized ethers of guar gum, which are described, for example, in 1980 TAPPI Retention & Drainage Seminar Notes, pp. 53-63 TAPPI Press 1980. The present invention is illustrated by means of two quarternized ethers of guar gum manufactured by Celanese Corporation, New York, NY: CP-13, the chemical structure of which is shown on page 55 in the aforementioned Seminar Notes and Celbond 22 (CB-22), described as a low charge cationic guar gum at page 59 of the same article. The structure of CP-13 is similar to the quaternary ammonium ethers disclosed and claimed in said U.S. Pat. No. 4,031,307.
When the present inventor sought to apply the general principle of fixing the anionic wet strength resin of U.S. Pat. No. 4,391,878, in particular a maleamic acid copolymer, to the anionic fibers of cellulose by means of a cationic substance, he found that nearly all of the materials which one of ordinary skill in the art to which the present invention pertains would be likely to select were ineffectual in accomplishing this purpose. Those tried to no avail are listed in TABLE A below.
Thus, the beneficial results of the present invention are especially surprising in view of the ineffectiveness of similar or analogous compounds typically used for sizing or web-strengthening purposes in the paper making art.
TABLE A
Cationic materials used with maleamic acid copolymer that gave no significant increase in cured or natural aged wet tensile.
1. Melamine formaldehyde resin (Scott Paper Company)
2. Urea formaldehyde resin (Scott Paper Company)
3. Parez 631NC (American Cyanamid)--glyoxalated polyacrylamide
4. Santores-31 (Monsanto)--polyamine epichlorohydrin
5. National Starch 1957--amphoteric corn starch
6. R.P.C. 1116 (Monsanto)
7. Potato starch (A. E. Staley Mfg. Co.)
8. Dimethylaminopropylmethacrylamide (Texaco)
9. Methacrylamidopropyltrimethylammonium chloride (Texaco)
10. Cato-2 (National Starch)--corn starch
11. Ammonia-epichlorohydrin polymer (Dow, U.S. Pat. No. 3,947,383)
Cationic materials used with maleamic acid copolymer that improved cured wet strength but did not develop significant wet strength on natural aging.
1. Alum
2. Kymene 557H (Hercules) polyamide--polyamine epichlorohydrin
3. Accurac 33 (American Cyanamid)
4. Accurac 33H (American Cyanamid)
5. Delfloc 50 (Hercules)
6. Reten 210 (Hercules) high molecular weight acrylamide copolymer
7. Accostrength 711 (American Cyanamid) polyacrylamide
8. Accostrength 514 (American Cyanamid) polyacrylamide
9. National Starch 1594 corn starch
10. Catomer Q (Richardson Co.)
11. FX-477 (Scott Paper Company, see example XIII)
DETAILED DESCRIPTION OF THE INVENTION
The principles, features and advantages of the invention will be further understood upon consideration of the following specific examples:
EXAMPLE I
Handsheets of paper were prepared employing laboratory apparatus to demonstrate the synergistic effect between ethylene maleamic acid and cationic guar gum. Northern kraft pulp (70% softwood and 30% hardwood) was refined to a Canadian freeness of 450-500 cc. In preparing each handsheet, a pulp slurry was made having a consistency of about 2.2% and containing 60 grams bone dry weight of pulp. The pulp slurry was placed in a British disintegrater which agitates the slurry. In set one (the pulp control) after ten minutes of agitation, the pH of the slurry in the disintegrater was adjusted to 4.0 with a 10% solution of H 2 SO 4 . After 15 minutes, the agitation was stopped and the pulp slurry poured into a proportioning tank of a Noble and Wood apparatus for making handsheets. The consistency of the slurry was adjusted in the tank to yield a handsheet having a basis weight of 20 pounds per ream (2,880 square feet). Several handsheets were then prepared from this slurry by metering a specific quantity of the pulp slurry into the deckle box of the Noble and Wood apparatus along with sufficient water and a final pH adjustment to 4.0 with 10% H 2 SO 4 to yield an 8 inch by 8 inch handsheet which was then pressed and dried on the pressing and drying section of the Noble and Wood apparatus. Test strips were then prepared from the handsheets and tested for both their dry and wet tensile strengths according to Tappi Standard No. T456M-49 on a Thwing-Albert Tensile Tester. To approximate direct off-machine tensiles the tensile strength tests were performed shortly after the sheets were produced. The tests were then repeated after two and four weeks of natural aging. Test strips of each handsheet were also subjected to high temperature curing for 3 minutes at 300° F. and the wet and dry tensile of the heat cured strips were also determined.
Set two was made in the same manner as set one except a one-half percent solution of CP-13 (a cationic guar gum manufactured by Celanese Corp.) was added to the slurry in the British disintegrater after one minute of mixing resulting in a 2% total solids addition of CP-13 based on fiber solids.
Set three was made in the same manner as set one except a 15.0% solution of the resin made in accordance with Example 2 of said U.S. Pat. No. 4,391,878 hereinafter designated "EMA" was added to the slurry in the British disintegrater after 3 minutes of mixing resulting in a 1.0% total solids addition of EMA based on fiber solids.
Set four was made in the same manner as set one except a 0.5% solution of CP-13 was added after one minute of mixing and a 15% solution of EMA was added after 3 minutes of mixing resulting in 2.0% solids addition of CP-13 and a 1.0% solids addition of EMA based on fiber solids.
Set five was made in the same manner as set one except a 0.5% solution of CB-123 (amphoteric guar gum manufactured by Celanese) was added after one minute of mixing resulting in a 2.0% total solids addition of CB-123 based on fiber solids.
Set six was made in the same manner as set one except a 0.5% solution of CB-123 was added after one minute of mixing and a 15% solution of EMA was added after 3 minutes of mixing resulting in a 2.0% solid addition of CB-123 and a 1.0% solids addition of EMA based on fiber solids.
Set seven was made in the same manner as set one except a 0.5% solution of CB-22 (a cationic guar gum manufactured by Celanese) was added after one minute of mixing resulting in a 2.0% total solids addition of CB-22 based on fiber solids.
Set eight was made in the same manner as set one except a 0.5% solution of CB-22 was added after one minute of mixing and a 15% solution of EMA was added after three minutes of mixing resulting in a 2.0% solids addition of CB-22 and a 1.0% solids addition of EMA based on weight of fiber solids.
The results of the eight sets of Example 1 are given in Table I.
SIGNIFICANCE
It can be seen from Table I that only slight gains in wet tensile are obtained when 2.0% CP-13 is added to the pulp furnish without EMA (set 2) and when 1.0% EMA is added to the pulp furnish without CP-13 (set 3). Set four shows the synergistic effect of sequentially adding both 2.0% CP-13 and 1.0% EMA to dramatically improve the wet strength properties of handsheets compared to sets 1, 2 and 3.
Although less effective than CP-13, the guar gums CB-123 and CB-22 will also provide a synergistic effect with EMA (set 6, vs. sets 1 and 5; set 8 vs. sets 1 and 7).
Table I represents the only type of chemicals found by the present invention which will retain EMA on the fiber to provide significant off machine wet tensile, cured wet tensile and natural aging wet tensile.
EXAMPLE II
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set two in Example I, except a 2% solids addition of FX-477 (a cationic dye fixative resin described in example XIII) replaced CP-13.
Set three was made in the same manner as set four in Example I except that a 2% solids addition of FX-477 replaced CP-13 in order to aid retention of the EMA.
Set four was made in the same manner as set four in Example I.
EXAMPLE III
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set two in Example I except that a 2% solids addition of Accurac 33 (cationic polymer manufactured by American Cyanamid) replaced CP-13.
Set three was made in the same manner as set four in Example I except that a 2% solids addition of Accurac 33 replaced CP-13 in order to aid retention of the EMA.
Set four was made in the same manner as set two in Example I except that a 2% solids addition of Accostrength 711 (cationic polymer made by American Cyanamid) replaced CP-13.
Set five was made in the same manner as set four in Example I except that a 2% solids addition of Accostrength 711 replaced CP-13 in order to aid retention of the ethylene maleamic acid.
Set six was made in the same manner as set two in Example I except that a 2% solids addition of Delfloc 50 (cationic polymer made by Hercules) replaced CP-13.
Set seven was made in the same manner as set four in Example I except that a 2% solids addition of Delfloc 50 replaced CP-13 in order to aid retention of the EMA.
SIGNIFICANCE
Tables II and III show that the cationic polymers FX-477, Accurac 33, Accostrength 711 and Delfloc 50 are capable of retaining some EMA on the fiber to produce heat cured wet strength but provide little off machine or natural age wet tensile. In other words, no wet strength is produced without heating the paper.
Other materials used in combination with EMA that provide heat cured tensile with little off machine or natural aging wet tensile development are Accurac 33H (American Cyanamid), Accostrength 514 (American Cyanamid), National Starch 1594, Reten (Hercules), and alum.
EXAMPLE IV
Set one, pulp control was made in the same manner as set one in Example I.
Set two was made in the same manner as set two in Example I except that 2.0% solids addition of CB-11 (anionic guar gum, Celanese) replaced CP-13.
Set three was made in the same manner as set four in Example I except that 2.0% solid addition of CB-11 replaced CP-13 prior to the addition of EMA.
Set four was made in the same manner as set two in Example I except that a 2% solids addition of cationic melamine-formaldehyde resin replaced CP-13.
Set five was made in the same manner as set four in Example I except that a 2% solids addition of cationic melamine-formaldehyde replaced CP-13 prior to the addition of ethylene maleamic acid.
Set six was made in the same manner as set four in Example I.
SIGNIFICANCE
The data in Table IV shows that anionic guar gum is not effective with EMA (sets 2 vs 3) and that melamine formaldehyde wet strength resin is far less effective than when used alone when combined in sequential addition with EMA (sets 4 vs 5).
There are a number of cationic compounds that when added sequentially with EMA produce little or no gain or a loss in off machine, heat cured and natural aging wet tensile. They include Santores-31 (Monsanto polyamine epichlorohydrin wet strength resin), urea-formaldehyde resin (according to U.S. Pat. No. 3,275,605), Dow Chemical's ammonia epichlorohydrin resin (U.S. Pat. No. 3,947,383), National Starch Cato 1597, Monsanto RPC 1116, American Cynamid Parez 631 NC, and cationic potato starch (A. E. Staley).
EXAMPLE V
Set one, pulp control was made in the same manner as set one in EXAMPLE I except that the pulp was 100% Northern softwood kraft which was used in all sets of Example V.
Set two was made in the same manner as set four in Example I.
Set three was made in the same manner as set four in Example I except that a 2% solids addition of a cationic urea-formaldehyde resin (U.S. Pat. No. 3,275,605) replaced CP-13 and no EMA was added to the pulp.
Set four was made in the same manner as set three, Example V except that 1% solids EMA was added to the pulp.
Set five was made in same manner as set four in Example I except that 2% solids addition of cationic Kymene 557H resin (Hercules) replaced CP-13 and no EMA was added to the pulp.
Set six was made in the same manner as set five in Example V except that 1% solids EMA was added to the pulp.
Set seven was made in the same manner as set four in Example I except that a 2% solids addition of a cationic base activated Santores-31 resin (Monsanto) replaced CP-13 and no EMA was added to the pulp.
Set eight was made in the same manner as set seven in Example V except that 1% solids of EMA was added to the pulp.
Set nine was made in the same manner as set four in Example I except that a 2% solids addition of a cationic Parez 631NC resin (American Cyanamid) replaced CP-13 and no EMA was added.
Set ten was made in the same manner as set nine in Example V except that 1% solids addition of EMA was added to the pulp.
The data obtained from Example V is shown in Table V.
SIGNIFICANCE
Table V shows that other common cationic wet strength resins such as urea-formaldehyde, Santores-31 and Parez 631NC are adversely effected by the sequential addition of EMA. The addition of EMA to a Kymene 557H treated pulp has little effect on wet strength properties.
EXAMPLE VI
Set one, pulp control, was made in the same manner as set one in Example I except the pH was adjusted to 7.0.
Set two was made in the same manner as set 4 in Example I except pH adjustment to 7.0.
Set three was made in the same manner as set 4 in Example I except the pH was adjusted to 6.0.
Set four was made in the same manner as set four in Example I except the pH was adjusted to 5.0.
Set five was made in the same manner as set four in Example I except the pH was adjusted to 4.0.
The data obtained from Example VI is shown in Table VI.
SIGNIFICANCE
The data in Table VI shows that the sequential addition of CP-13 and EMA will produce off machine, heat cured and natural aging wet strength throughout the pH range of 4.0 to 7.0. However, the CP-13/EMA system is far more effective as the pH is lowered.
EXAMPLE VII
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set two in Example I except 1% CP-13 treatment on pulp.
Set three was made in the same manner as set two in Example I.
Set four was made in the same manner as set two in Example I except the CP-13 treatment was increased to 4%.
The data obtained from Example VIII is shown in Table VII.
EXAMPLE VIII
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set four in Example I except 0.25% CP-13 was used.
Set three was made in the same manner as set four in Example I.
Set four was made in the same manner as set four in Example I except that 4.0% CP-13 was used.
Set five was made in the same manner as set four in Example I except that 4.0% CP-13 and 0.25% EMA were used.
Set six was made in the same manner as set two in Example I except that 4.0% CP-13 was used.
The data obtained from Example VIII is shown in Table VIII.
EXAMPLE IX
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set four in Example I except that 2% EMA was added.
Set three was made in the same manner as set four in Example I.
Set four was made in the same manner as set four in Example I except that 0.5% EMA was added.
Set five was made in the same manner as set four in Example I except that 0.25% EMA was added.
Set six was made in the same manner as set four in Example I except that 0.125% EMA was added.
Set seven was made in the same manner as set four in Example I except that 0.0625% EMA was added.
The data obtained from Example IX is shown in Table IX.
EXAMPLE X
Set one, pulp control, was made in the same manner as set one in Example I except the pulp was 100% Northern softwood kraft which was used in all sets of Example X.
Set two was made in the same manner as set four in Example I except that 1% CP-13 was added.
Set three ws made in the same manner as set four in Example I except that 1% CP-13 and 2% EMA were added.
Set four was made in the same manner as set four in Example I except that 1% CP-13 and 4% EMA were added.
Set five was made in the same manner as set four in Example I except that 1% CP-13 and 8% EMA were added.
Set six was made in the same manner as set four in Example I except that 8% EMA was added.
Set seven was made in the same manner as set four in Example I except that 4% CP-13 and 8% EMA were added.
Set eight was made in the same manner as set four in Example I except that 8% CP-13 and 8% EMA were added.
Set nine was made in the same manner as set eight in Example X except that no CP-13 was added.
The data obtained from Example X is shown in Table X.
EXAMPLE XI
Set one, pulp control was made in the same manner as set one in Example I except the pulp was 100% Northern softwood kraft which was used for all sets of Example XI.
Set two was made in the same manner as set three in Example I except 0.5% EMA was added.
Set three was made in the same manner as set three in Example I.
Set four was made in the same manner as set three in Example I except that 2% EMA was added.
Set five was made in the same manner as set three in Example I except that 4% EMA as added.
Set six was made in the same manner as set three in Example I except that 8% EMA was added.
The data obtained from Example XI is shown in Table XI.
SIGNIFICANCE
The data in Table VII shows that large amounts of CP-13 can be added to pulp without any significant change in wet tensile compared to the pulp control. The data in Table XI shows that large amounts of EMA can be added to pulp with only slight gains in wet tensile compared to the pulp control. Some EMA is retained in the handsheet via entrapment and the 100% Northern softwood kraft used in Example XI is a stronger pulp than the 70%/30% Northern softwood/Northern hardwood kraft used in Example VIII.
The data contained in Tables VIII, IX and X clearly shows the syn-ergistic effect of combining various amounts of CP-13 and EMA.
As may be seen from Tables VIII, IX and X, if a specified amount of Cp-13 is added to the pulp then the amount of EMA can be optimized (using wet tensile as the main criteria). Furthermore, each increase in the amount of CP-13 added permits more EMA to be retained, which results in increased set tensile.
EXAMPLE XII
Set one, pulp control, was made in the same manner as set one in Example I.
Set two was made in the same manner as set two in Example I, except a 1% solids addition of Cato-2 (cationic corn starch from National Starch) replaced CP-13.
Set three was made in the usual manner as set four in Example I, except that a 1% solids addition of Cato-2 replaced CP-13 in order to aid retention of EMA.
SIGNIFICANCE
Table XII shows that cationic corn starch is capable of retaining some EMA on the fiber to produce a small amount of heat cured wet tensile but provides little or no off-machine or natural age wet tensile. In other words, no wet strength is produced without heating the paper.
EXAMPLE XIII
60.6 grams of hexamethylene tetramine, 86.2 grams of ammonium sulfate, 99.2 grams of dicyandiamide, 373.1 grams of 37% formaldehyde and 339.9 grams of water were placed in a three neck flask equipped with a mechanical stirrer, thermometer and condenser. The mixture was agitated for ten minutes prior to heating. Then the mixture was heated over a 30 minute period to a temperature of 175° F. and maintained between 170°-180° F. for 2 hours. The resin was cooled to 140° F. and 43.1 grams of urea was added to the solution and mixed for 10 minutes. Then 18.5 grams of 37% formaldehyde was added to the resin and mixed for 5 minutes. Adjust the pH of the resin to 7.5-8.0 with 68.6 grams of 10% sodium hydroxide solution. Cool the resin to room temperature and readjust pH to 7.5-8.0 range if necessary. The resulting reaction mixture had a viscosity of 20.4 centistokes at 25° C., a pH of 8.0 and a non-volatile solids content of 34.8%. The resin is designated herein as FX477.
It is apparent that other variations and modifications may be made without departing from the present invention. Accordingly, it should be understood that the forms of the present invention described above are illustrative and not intended to limit the scope of the invention.
TABLE I__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 1.3 176.0 0.7 1.9 173.3 1.1 1.1 184.6 0.6 2.0 182.3 1.12 4.02 CP-13 -- 3.9 207.3 1.9 6.0 206.7 2.9 4.6 212.0 2.2 5.3 253.1 2.13 4.0-- 1.0 2.1 172.0 1.2 6.8 183.5 3.7 1.3 182.9 0.7 3.0 202.9 1.54 4.02 CP-13 1.0 54.6 207.0 26.4 74.3 239.0 31.1 52.9 243.4 21.7 65.4 253.7 25.85 4.0 2 CB-123 -- 8.0 205.5 3.9 14.6 220.5 6.6 9.3 219.4 4.2 12.1 244.0 5.06 4.0 2 CB-123 1.0 25.9 213.0 12.2 51.4 226.5 22.7 27.6 230.9 12.0 34.3 266.9 12.97 4.02 CB-22 -- 4.3 205.5 2.1 10.4 220.0 4.7 6.3 213.7 2.9 8.9 220.6 4.08 4.02 CB-22 1.0 23.9 212.0 11.3 51.3 233.5 22.0 27.1 224.6 12.1 33.4 235.4 14.2__________________________________________________________________________
TABLE II__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 1.1 169.3 0.6 1.9 177.0 1.1 2.0 166.0 1.2 2.4 193.0 1.22 4.02 FX-477 -- 1.5 174.3 0.9 5.1 184.5 2.8 3.3 160.0 2.1 2.0 190.5 1.03 4.02 FX-477 1.0 3.0 179.0 1.7 49.3 202.65 24.3 8.0 180.0 4.4 9.5 204.5 4.64 4.02 CP-13 1.0 58.0 233.0 24.9 80.4 256.5 31.3 60.3 245.3 24.6 74.1 244.0 30.4__________________________________________________________________________
TABLE III__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 2.8 204.5 1.4 5.4 194.9 2.8 3.8 193.5 2.02 4.02 Accurac -- 2.8 212.0 1.3 11.8 197.5 6.0 2.8 197.5 1.4333 4.02 Accurac 2.0 6.9 213.0 3.2 54.9 210.0 26.1 13.0 199.0 6.5334 4.02 Acco- -- 2.9 232.0 1.3 20.8 211.0 9.9 4.3 201.1 2.1Strength7115 4.02 Acco- 2.0 2.6 201.5 1.3 26.1 201.7 12.9 5.5 204.6 2.7Strength7116 4.02 DelFloc -- 4.8 202.9 2.4 25.4 190.3 13.3 9.6 182.0 5.3507 4.02 DelFloc 2.0 6.6 216.6 3.0 46.1 208.0 22.2 12.6 182.0 6.950__________________________________________________________________________
TABLE IV__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 1.0 162.4 0.6 2.6 175.3 1.5 3.0 160.7 1.9 1.4 173.7 0.82 4.02 CB-11 -- 1.5 170.5 0.9 5.0 190.2 2.6 4.1 169.3 2.4 4.5 180.2 2.53 4.02 CB-11 1.0 1.7 178.0 1.0 8.5 202.0 4.2 5.3 192.0 2.8 5.7 186.9 3.04 4.02 M.F. -- 70.9 216.5 32.9 90.4 240.5 37.6 73.7 237.3 31.1 88.1 270.9 32.55 4.02 M.F. 1.0 12.7 184.5 6.9 39.5 197.0 20.1 16.8 164.0 10.2 16.9 188.6 9.06 4.02 CP-13 1.0 54.6 211.0 25.9 73.0 236.0 30.9 60.3 185.3 32.5 67.9 276.0 24.6__________________________________________________________________________
TABLE V__________________________________________________________________________ 2 Week Natural 4 Week Off Machine Cured 3' @ 300° F. Tensile Natural AgingConditions Tensile Tensile Tensile % Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry Wet/ Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Dry In In Dry__________________________________________________________________________1 4.0-- -- 6.0 241.3 2.5 6.6 253.5 2.6 4.8 268.5 1.8 3.9 276.0 1.42 4.02 CP-13 1.0 61.8 256.0 24.1 91.3 264.5 34.5 66.0 270.0 24.4 66.7 309.1 21.63 4.02 U.F. -- 32.9 237.5 13.9 114.5 267.5 41.4 67.0 273.1 24.5 80.1 292.6 27.44 4.02 U.F. 1.0 16.4 238.5 6.9 31.4 259.5 12.1 25.6 252.0 10.2 25.3 275.4 9.25 4.02 KY557H -- 14.0 211.5 6.6 42.1 233.5 18.0 23.3 241.7 9.6 32.4 252.0 12.96 4.02 KY577H 1.0 14.5 219.0 6.6 54.5 238.0 22.9 22.3 229.7 9.7 23.4 256.0 9.17 4.02 -- 23.3 224.5 10.4 82.6 248.5 33.3 35.6 241.7 14.7 42.7 253.1 16.9SANTORES-318 4.02 1.0 19.4 224.0 8.7 64.4 253.0 25.5 25.7 256.0 10.0 28.3 266.3 10.6SANTORES-319 4.02 PAREZ -- 95.1 277.5 34.3 101.3* 271.5* 37.3* 98.3 278.9 35.2 102.4 308.0 33.263110 4.02 PAREZ 1.0 82.6 271.5 30.4 79.0* 279.5* 28.3* 84.9 271.4 31.3 84.6 315.4 26.8631__________________________________________________________________________ *Sample heat cured for 30' at 105° C.
TABLE VI__________________________________________________________________________ 2 Week Natural 4 Week Off Machine Cured 3' @ 300° F. Tensile Natural AgingConditions Tensile Tensile Tensile % Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry Wet/ Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Dry In In Dry__________________________________________________________________________1 7.0-- -- 3.3 176.0 1.9 1.0 176.0 0.6 3.6 173.3 2.1 2.3 198.0 1.22 7.02 CP-13 1.0 9.4 241.9 3.9 55.6 246.0 22.6 23.3 215.3 10.9 28.5 232.6 12.33 6.02 CP-13 1.0 24.0 280.0 8.6 67.3 233.0 28.9 34.7 222.7 15.6 42.6 236.0 18.14 5.02 CP-13 1.0 34.0 236.6 14.4 61.1 224.0 27.3 40.9 233.3 175. 47.3 256.6 18.45 4.02 CP-13 1.0 52.7 226.3 23.3 74.6 240.6 31.0 51.8 208.7 24.8 56.4 237.7 23.7__________________________________________________________________________
TABLE VII__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 2.8 197.1 1.4 5.4 184.0 2.9 2.4 177.7 1.4 3.8 188.5 2.02 4.01% CP-13 -- 3.8 225.5 1.7 5.9 200.5 2.9 4.3 195.0 2.2 5.8 192.0 3.03 4.02% CP-13 -- 3.8 227.0 1.7 6.8 199.0 3.4 4.4 207.5 2.1 6.4 184.5 3.54 4.04% CP-13 -- 4.4 224.5 2.0 6.8 195.5 3.5 4.4 191.5 2.3 5.5 192.5 2.9__________________________________________________________________________
TABLE VIII__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 1.3 167.2 0.8 3.3 204.5 1.6 3.2 169.3 1.9 1.1 184.6 0.62 4.0.25% 1.0 16.6 214.5 7.7 50.3 248.0 20.3 24.7 208.7 11.8 31.4 218.9 14.3CP-133 4.02.0% 1.0 47.8 248.0 19.3 95.0 264.5 35.9 59.3 245.3 24.2 70.7 222.3 31.8CP-134 4.04.0% 1.0 55.6 237.7 23.4 94.6 272.0 34.8 63.2 236.0 26.8 73.4 240.6 30.5CP-135 4.04.0% .25 32.0 235.0 13.6 61.1 269.7 22.7 43.3 229.3 18.9 45.3 213.7 21.1CP-136 4.04.0% -- 6.7 193.5 3.5 16.4 247.0 6.6 11.8 206.0 5.7 13.6 209.1 6.5CP-13__________________________________________________________________________
TABLE IX__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 2.1 193.1 1.1 4.6 183.4 2.5 3.4 175.4 1.9 4.5 183.5 2.52 4.02 CP-13 2.0 41.5 240.6 17.2 72.5 239.5 30.3 50.4 216.5 23.3 54.5 235.0 23.23 4.02 CP-13 1.0 39.6 253.5 15.6 77.8 232.5 33.5 48.0 230.5 20.8 50.3 227.5 22.14 4.02 CP-13 0.5 34.9 229.0 15.2 66.7 220.5 30.2 45.5 213.0 21.4 46.4 234.5 19.85 4.02 CP-13 0.25 28.9 228.0 12.7 55.1 221.5 24.9 39.4 207.0 19.0 40.8 241.5 16.96 4.02 CP-13 0.125 20.5 218.3 9.4 49.0 207.5 23.6 27.5 202.0 13.6 30.4 202.5 15.07 4.02 CP-13 0.0625 16.9 211.0 8.0 43.3 217.7 19.9 24.6 204.0 12.1 23.5 201.0 11.7__________________________________________________________________________
TABLE X__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Natural AgingConditions Tensile Tensile Tensile Tensile Wet Dry %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Oz/ Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In In Dry__________________________________________________________________________1 4.0-- -- 4.5 225.5 2.0 6.3 220.5 2.9 3.9 213.7 1.8 5.3 249.6 2.12 4.01 CP-13 1.0 46.3 280.0 16.5 91.9 282.5 32.9 61.7 272.6 22.6 87.1 304.0 28.73 4.01 CP-13 2.0 44.3 272.5 16.3 90.1 276.5 32.7 58.1 268.0 21.7 80.3 302.3 26.64 4.01 CP-13 4.0 46.5 286.5 16.2 98.4 300.7 32.7 67.0 272.6 24.6 87.3 290.3 30.15 4.01 CP-13 8.0 47.1 294.0 16.6 105.6 292.0 36.2 71.9 285.1 25.2 90.4 311.4 29.06 4.02 CP-13 8.0 76.8 298.3 25.7 117.1 299.5 39.1 80.4 296.6 27.1 108.9 326.9 33.37 4.04 CP-13 8.0 88.6 296.5 29.9 125.1 286.5 43.7 93.7 312.0 30.0 121.1 313.1 38.78 4.08 CP-13 8.0 89.0 273.5 32.5 128.6 280,5 45.0 97.3 264.6 36.8 120.9 305.1 39.69 4.0-- 8.0 6.9 215.0 3.2 28.3 223.0 12.7 9.9 204.0 4.9 14.4 237.7 6.1__________________________________________________________________________
TABLE IX__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Aging Natural AgingConditions Tensile Tensile Tensile Tensile Wet %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Dry Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In Oz/In Dry__________________________________________________________________________1 4.0-- -- 4.6 216.5 2.1 6.0 224.5 2.7 4.0 236.6 1.7 3.4 274.9 1.22 4.0-- .5 5.0 231.5 2.2 7.8 232.5 3.4 4.4 242.3 1.8 3.7 288.0 1.33 4.0-- 1.0 4.3 215.5 2.0 7.9 225.0 3.5 3.4 231.4 1.5 5.0 274.3 1.84 4.0-- 2.0 4.0 233.5 1.7 9.3 228.0 4.1 3.6 236.6 1.5 6.0 273.7 2.25 4.0-- 4.0 4.5 237.0 1.9 11.6 234.9 4.9 4.9 241.7 2.0 5.7 273.7 2.16 4.0-- 8.0 3.9 214.0 1.8 12.6 227.5 5.5 5.6 212.6 2.6 4.6 259.4 1.8__________________________________________________________________________
TABLE XI__________________________________________________________________________ 4 Week Off Machine Cured 3' @ 300° F. 2 Week Natural Aging Natural AgingConditions Tensile Tensile Tensile Tensile Wet %Set % % Wet Dry % Wet Dry % Wet Dry % Oz/ Dry Wet/# pHAdditive EMA Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry Oz/In Oz/In Wet/Dry In Oz/In Dry__________________________________________________________________________1 4.0-- -- 2.6 180.0 1.4 1.8 200.6 0.9 2.6 186.9 1.4 4.1 184.6 2.22 4.01.0 -- 2.0 209.1 1.0 6.6 205.0 3.2 2.1 198.9 1.1 3.3 208.6 1.6CATO-23 4.01.0 1.0 1.9 197.1 1.0 11.9 205.7 5.8 4.0 196.0 2.0 4.9 201.7 2.4CATO-2__________________________________________________________________________
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Cationic polygalactomannan gums and water soluble wet strength resins containing an amic acid and at least one other ethylenically unsaturated monomer, are useful in the preparation of products having improved, off-machine dry strength and wet strength properties.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a device for holding a middle portion of a measuring tape measure in place while making measurements.
2. Description of the Related Art
Measuring tape in tape measures can often be lengthy. Their length can be as much as several hundred feet in length. The measuring tape may be rolled up as a coil within the tape measuring case when the tape measure is not in use. When in use, the end of the measuring tape is pulled and the measuring tape is extracted from the case.
Measuring tapes come in a variety of shapes and sizes. Measuring tape can be made of metal, fiberglass or cloth. The leading end of the measuring tape can have a small, right angled piece of metal attached thereto enabling the user to grip the measuring tape and enabling the end of the measuring tape to be placed on an edge of a structure like a table top when measuring the dimensions of an object. The other end of the measuring tape may be coiled tape inside the case and is carried by the measurer. A problem occurs when the user wishes to measure long distances using measuring tape from a tape measure. Although the small piece of metal at the end of the measuring tape can be secured on an edge of an object, and the other end can be carried by the measurer, a problem occurs in that the middle portions of the measuring tape can move during measurement, especially if the distance being measured is very large. This is because the measuring tape is flexible, and when measuring long distances, the measuring tape often bends and wobbles thereby adding to the difficulty in obtaining an accurate measurement for a long distances.
What is needed is one or more holders that can secure in between portions of the measuring tape between the ends of the measuring tape when making a measurement. The holder is to be tube shaped, but having a slit to enable a middle portion of the measuring tape to be inserted into the holder, instead of requiring an end portion of the measuring tape to be fed through the holder while measuring to secure in between portions of the measuring tape in place when making large measurements. Furthermore, what is needed is a magnet attached to the tape holder(s) to allow the tape holder and thus the measuring tape to be attached to a metallic object during measurements. Such metal objects could be a steel beam on the roof of the structure, a metal object, or a metal wall, floor or roof such as those found in metal shops or ships. Such holder or holders will enable the user to more easily make measurements using the measuring tape of a tape measure in any direction, whether it is up and down or across the floor or ceiling.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a holder for a measuring tape that can secure in place a middle portion of the measuring tape when a large measurement is taken by a measuring tape.
It is further an object of the present invention to provide an opening in the holder to allow the measuring tape to be inserted into the holder without having to feed through the end of the measuring tape into the holder.
It is also an object of the present invention to provide a magnet attached to the holder to secure the holder and thus the measuring tape to metallic objects and structures.
It is still an object of the present invention to provide a holder or a plurality of holders to enable easier measurements using a measuring tape in all directions, such as up and down, or across a ceiling, floor or some other structure.
It is also an object of the present invention to provide a process for making the measuring tape holder.
It is further an object of the present invention to provide a method for using the measuring tape holder to measure distances in a variety of directions.
These and other objects can be achieved by a guide or holder for a measuring tape. Either the end of the measuring tape can be inserted through the guide or the measuring tape can be inserted into the guide through a slit that runs the entire length of the guide. The guide is essentially tubular in structure to guide a measuring tape that runs within the tube. One side of the tube has a slit opening along the entire length of the guide for insertion of a middle portion of a measuring tape into the guide or holder. Further, the holder or guide has a magnet attached thereto. The magnet can be used for attaching the guide to a metallic object such as a beam, a pipe or a sheet or piece of metal thereby securing a portion of the tape measure in place. By having a middle portion of the measuring tape inserted into the guide, measurements of long distances by a measuring tape becomes much more simpler and more reliable as the measuring tape is not as likely to bend, wobble or move during the course of making a measurement. Attachment of the holder by the magnet to vertical metal structures like a pipe or horizontal structures like a beam makes vertical measurements or horizontal measurements along a ceiling using a measuring tape much more easier, quicker and more reliable, especially if only one person is available to make the measurement. The novel guide can be used with measuring tapes made of various materials such as metal, cloth or fiberglass.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIG. 1 illustrates a completely assembled measuring tape holder guide according to the principles of the present invention;
FIG. 2 illustrates the measuring tape holder guide of FIG. 1 guiding a measuring tape according to the principles of the present invention;
FIG. 3 illustrates a end view of the measuring tape measure holder guide guiding a measuring tape according to the principles of the present invention;
FIG. 4 illustrates the measuring tape holder part of the tape measure holder guide of FIG. 1 ;
FIG. 5 illustrates the magnet holder part of the measuring tape holder guide of FIG. 1 ;
FIG. 6 illustrates the magnet found in the measuring tape holder guide of FIG. 1 ;
FIG. 7 illustrates one of many uses for the measuring tape holder part for making a vertical measurement; and
FIG. 8 illustrates another use for the novel measuring tape holder for measuring a horizontal distance along a ceiling.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a view of a fully assembled measuring tape guide 10 according to the principles of the present invention. The measuring tape guide 10 is made up of measuring tape holder part 20 , magnet holder 50 and magnet 75 . As illustrated in FIGS 1 and 4 , measuring tape holder part 20 is essentially a rectangular-shaped tube with a right side 35 , a left side 37 , a bottom side 40 and a top side 27 . The top side has a slit opening 45 along a length of the top side 27 of measuring tape holder part 20 . The top side 27 therefore has a right top portion 25 and a left top portion 30 divided by slit 45 . The tape holder part 20 may be of some other cross sectional shape, but rectangular is preferred.
Attached to the left side 37 of measuring tape holder part 20 is a U-shaped magnet holder part 50 . As illustrated in FIGS. 1 and 5 , the magnet holder part 50 has a top side 60 , a bottom side 55 and a right side 65 . The right side 65 joins the top side 60 with the bottom side 55 of magnet holder part 50 . The right side 65 of magnet holder part 50 is welded to the left side 37 of measuring tape holder part 20 by weld 70 . Alternatively, the right side 65 of magnet holder part could instead be welded to right side 35 of measuring tape holder part 20 . I have found that it is not preferable to weld magnet holder part 50 to the bottom side 40 (the side opposite from slit 45 ) of tape holder part 20 as the measuring tape, in such a configuration, could fall out through the slit 45 if the magnet 75 is attached to a metallic ceiling structure such as a metallic beam. Preferably, weld 70 is actually four tack welds of 0.125×0.375 inches long and 0.125 inches in from each corner, but other weld configurations are possible. Magnet holder part 50 is absent a left side so that magnet 75 can be inserted into magnet holder part 50 .
Magnet 75 is preferably glued to magnet holder part 50 via glue and is also attached to the magnet holder 50 and measuring tape holder part 20 via screws 80 . I have found that absent the screws 80 , the magnet 75 would separate from the magnet holder part 50 if tape measure guide 10 is dropped. Therefore, screws 80 and the accompanying screw holes are highly recommended. Holes for screws 80 are drilled through magnet 75 , through the right side 65 of magnet holder 50 and through the left side 37 of measuring tape holder 20 . The holes drilled in magnet holder 50 and measuring tape holder 20 are preferably via a drill with a #29 drill bit and preferably tapped for a #8 machine screw. The holes drilled through magnet 75 are often done before assembly in a mass production environment. Preferably, the diameter of the drill holes are 0.187 inches with a 0.12 inch countersink with a 100 degree angle.
FIG. 2 illustrates measuring tape guide 10 of FIG. 1 with measuring tape 90 disposed within measuring tape holder part 20 . Measuring tape 90 may be made of metal, fiberglass or cloth. Measuring tape 90 is inserted into measuring tape holder part 20 through slit 45 . Slit 45 enables measuring tape 90 to be inserted within the measuring tape holder part 20 without requiring an end of the measuring tape to be fed through the measuring tape holder part 20 . This slit 45 feature can come in handy when the tape measure is very long and the measuring tape guide 10 is to secure a middle portion of the measuring tape 90 . In such a scenario, it would be inconvenient to have to feed the tape in through the tape holder part 20 . Slit 45 prevents the necessity of having to feed through the entire measuring tape 90 in order for measuring tape guide 10 to guide or hold tape 90 .
FIG. 3 illustrates an end view of the measuring tape guide 10 illustrated in FIG. 1 . Like FIG. 2 , the measuring tape guide 10 is made up of measuring tape holding part 20 with slit 45 extending the length of the measuring tape holder part. Magnet holder 50 is attached by welds W to one of the two external surfaces of the measuring tape holder part that is adjacent to the portion of the measuring tape holding part that bears the slit 45 . Magnet 75 is disposed within the magnet holder 50 and is permanently attached to the magnet holder 50 and the measuring tape holding part 20 by screws 80 and glue.
FIG. 4 illustrates measuring tape holder part 20 . FIG. 4 illustrates the preferable dimensions of the tape holder part 20 . In no way is this invention limited to the exact dimensions illustrated in FIG. 4 .
Preferably, tape holder part 20 is preferably made of 14 gauge A 36 steel, however, in no way is this invention limited to the exact materials mentioned. For example, the tape holder part 20 could instead be made of plastic. Top side 27 , bottom side 40 , left side 37 and right side 35 are preferably 2 inches in length. Left side 37 and right side 35 are 1.625 inches tall. Bottom side 40 is preferably 1.375 inches wide. Slit 45 is preferably 0.375 inches wide thereby leaving right top side 25 and left top side 30 preferably 0.5 inches wide. Holes 82 for screws 80 are disposed on a side ( 37 as illustrated or 35 ) of the tape holder part 20 that is adjacent to the side bearing the slit 45 and preferably not on a side 40 of the measuring tape part that is opposite to the slit 45 . FIG. 4 illustrates the preferred positioning of the holes 82 , however, in no way is this invention limited to the exact dimensions listed in FIG. 4 .
FIG. 5 illustrates magnet holder 50 . FIG. 5 illustrates the preferred dimensions of magnet holder 50 . Preferably, magnet holder part 50 is made of 14 gauge A 36 steel however it is also possible to use plastic. Preferably, top side 60 and bottom side 55 are 2 inches long and 0.5 inches wide. Preferably, right side 65 is 2 inches long and 1.0 inch high. Holes 85 are drilled to accommodate the screws 80 . Holes 85 must line up with and be the same size as holes 82 in FIG. 4 for the invention to work. In no way is magnet holder part 50 limited by the dimensions and materials specified herein. Right side 65 of magnet holder has an inside side and an outside side. It is the outside side of right side 65 that is welded to the tape holder part 20 and it is the inside side of side 65 that is glued to the magnet 75 .
FIG. 6 illustrates magnet 75 . Preferably, magnet 75 is 0.387 inches thick, 0.875 inches high and 1.875 inches long. Holes 87 are formed before production to accommodate screws 80 . Holes 87 must line up and be the same size as holes 85 in FIG. 5 and holes 82 in FIG. 4 in order to properly fasten magnet 75 to magnet holder 50 and tape holder part 20 via screws 80 . In no way is magnet 75 limited to the dimensions of FIG. 6 .
Now, the process for making the measuring tape guide 10 will be described. Magnets 75 with holes 87 are formed in a mass production environment. Then, the right side 65 of magnet holder 50 is welded to the left side 37 of tape holder part 20 . Instead, the magnet holder 50 can be welded to the right side 35 of tape holder part 20 , but for this explanation, it will be assumed that the magnet holder 50 is welded to the left side 37 of tape holder part 20 . Then, the holes 85 in the magnet holder and the holes 82 in the tape holder part are drilled and tapped. The combination of magnet holder 50 welded to tape holder part 20 is then sandblasted to clean the parts. Masking tape is then placed on the inside side of right side 65 of magnet holder 50 . This is because this inside side of side 65 of magnet holder 50 will later be glued to the magnet 75 and it is preferred that this inside side of right side 65 is not painted before the glueing. This is because painting the surfaces used for glueing may provide a poorer bond than of the glued surfaces are not painted. Then, the combination magnet holder 50 welded to the tape holder part 20 is painted, preferably by spray paint. After the painting, the masking tape is removed from the inside surface of right side 65 of magnet holder 50 . Glue is applied to the inside surface of right side 65 of magnet holder 50 and to one side of the magnet 75 . Then, the magnet 75 is attached to the magnet holder 50 so that the holes 87 line up with the holes 85 and 82 . Lastly, the screws 80 are inserted into the holes 87 of magnet 75 , the holes 85 of the magnet holder 50 and holes 82 of the tape holder part 20 thereby completing the construction process. The above described process for making measuring tape holder 10 is the preferred process but in no way is the only way to build the measuring tape holder 10 .
Turning to FIG. 7 , FIG. 7 illustrates the one use for a plurality of measuring tape holders for measuring a vertical distance along a metallic pipe. As illustrated in FIG. 7 , pipe 110 runs up and down in a room. A plurality of measuring tape holders 10 are attached to pipe 110 . It is the magnet 75 in magnet holder 50 that is stuck onto the pipe 110 . Then, tape 90 is inserted into the slits 45 of tape holder part 20 of measuring tape guide 10 to measure a distance in the vertical direction. Because of the presence of the plurality of measuring tape holders 10 stuck to pipe 110 , a vertical measurement can more easily be made, especially if there is only one person present to make the measurement.
FIG. 8 illustrates another use for a plurality of measuring tape holders 10 . In FIG. 8 , there is a horizontal beam 120 that runs across a ceiling. As in FIG. 7 , the measuring tape holders are placed on the horizontal beam 120 by attaching the magnet 75 of each measuring tape holder 10 to the beam 120 . After the measuring tape holders 10 are attached to the beam 120 , the user inserts measuring tape 90 into slit 45 of each measuring tape holder 10 to make the measurement. Since the magnet 75 and the magnet holder 50 are attached to an exterior surface of the tape holder part 20 that is adjacent to and not opposite to the exterior surface bearing the slit 45 , the tape 90 will not fall out through slit 45 in the arrangement of FIG. 8 when a measurement is being made. This is because the slit 45 is facing sideways and not down, preventing the tape 90 from inadvertently falling out through slit 45 during the measurement. By using the measuring tape holder 10 in the strategic manner as illustrated in FIG. 8 , a single person can much more easily make measurements along a ceiling with a measuring tape of a tape measure.
It is to be appreciated that measuring tape holder 10 is not limited in any way by the uses illustrated in FIGS. 7 and 8 . Measuring tape holder 10 is an all position tool capable of making measuring tape measurements easier in all directions.
It is to be appreciated that the present holder enables easy securing of a measure tape at a middle portion of the measuring tape when a measurement is taking place without requiring the user to feed through the entire tape into each holder. The holder secures a middle or in between portion of the tape in place making it easier to make big measurements in any direction using a measure tape. As illustrated in FIGS. 7 and 8 , many holders may be used in making a measurement using a measuring tape, especially if the distance being measured is very large.
It is noted that the present invention is not limited to the preferred embodiment described above, and it is apparent that variations and modifications by those skilled in the art can be effected within the spirit and scope of the present invention defined in the appended claims.
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A holder and guide for a measuring tape and a process of making and using the holder. The holder is made up of a hollow tube having a rectangular cross section. The tube has a slit or gap running the length of the tube to enable a measuring tape to be inserted. A magnet is attached to an exterior portion of the tube. The holder enables a user to insert any portion of a measuring tape inside the tube without having to insert the end of the tape measure therein. The holder facilitates in making measurements using a measuring tape, especially when a long distance is being measured and it is inconvenient to insert an end of the measuring tape through the guide to secure a middle portion of the measuring tape during measurement. The holder also has a magnet that attaches the holder to metallic objects enabling a single user to more easily make measurements using a measuring tape.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending European Patent Application No. EP07113715, filed 2 Aug. 2007, which is hereby incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of computer data encrypting and decrypting, especially for compact or low performance or power devices such as smartcards or nomad and mobile computerized objects.
BACKGROUND OF THE INVENTION
[0003] In encryptography, more and more processing power is required to encipher or decipher texts or data. This often calls for dedicated “hardware assist” components which need substantial computer resources (memory, CPU cycles) which themselves ask for significant energy sources. On mobile equipment such as PDAs, mobile phones, smart cards and the like, it is desirable to have systems which present a good trade-off between power consumption and security strength.
SUMMARY OF THE INVENTION
[0004] In one embodiment, the invention comprises processing at least one pseudo-random sequence of numbers generated from at least one first key for encrypting or decrypting data. Generation of this pseudo-random sequence of numbers comprises an iteration of a function termed pseudo-random function, which is defined as comprising the following steps: testing a determined test condition on a first number from this sequence; in at least a first case of said test condition, applying on said first number a first operation; in at least a second case of this test condition, applying on this first number a second operation; using result of this first operation or second operation for obtaining a second number, this second number taking place in this sequence after this first number.
[0005] First and second operations are two different arithmetical functions. They are selected so as, for at least one of these two operations, when a first number is processed through such operation issuing a second number, the result of the test condition on the second number is not systematically identical to the result of the test condition on the first number. Preferably, both first and second operations are selected under such a condition.
[0006] As an example, if the test condition is a parity test, any function which may never cause a parity change cannot be chosen as such an operation. Thus, adding an even number or multiplying with an even number may not be selected as such an operation. This potential change of test condition between first and second number of the pseudo-random sequence is a factor for a more randomly distributed sequence.
[0007] Preferably, the invention proposes to generate the second number through a function of the Collatz type, as defined hereafter. In a preferred embodiment, the first number is an integer and the step of checking the test condition comprises calculating parity of this first number. Parity computing is quite simple and fast done in binary circuits, and enables good performance with low complexity and power consumption.
[0008] In alternative embodiments, the test condition may comprise calculating a value of this first number under a modular equality. As an example, the method according to the invention may involve three cases and three operations, depending on a test condition of equality modulo 3.
[0009] According to embodiments of the invention, the pseudo-random sequence of numbers is used for encrypting or decrypting binary data, through a method comprising the following steps: generating the pseudo-random sequence of numbers from a first key data, termed starting number, treated as an initial first number for this pseudo-random sequence of numbers; processing this pseudo-random sequence of numbers through a conversion treatment resulting into a pseudo-random of binary digits; applying a encyphering or decyphering treatment, using this binary pseudo-random sequence as a seed for encrypting or respectively decrypting computer data.
[0010] Preferably, first and second operations are chosen such that the result of applying the first operation on the first number is greater than this first number, while the result of applying the second operation on this same first number is lesser than this first number, or reversely. This feature enables the sequence to involve numbers staying relatively low, thus minimizing the need for large binary registers or memories. Also, it combines well with the conversion treatment described hereabove for issuing a more randomly distributed pseudo-random binary sequence. For a better device simplicity and an optimal trade-off between different technical constraints, as well as a better “random quality” or unpredictability of the pseudo-sequences generated, the invention proposes using functions with the following features, as first and/or second operations: applying the first operation on the first number comprises dividing this first number by a determined number greater than one; applying the second operation on the first number comprises multiplying this first number by another number greater than one, the result of which being further added with an odd number.
[0011] Furthermore, according to embodiments of the invention, the test condition and first and second operations involve the following features. The step of checking the test condition results in the first case when the first number parity is even. The step of applying the first operation to this first number then comprises dividing this first number by an even integer. Meanwhile, the step of checking the test condition results in the second case when the first number parity is odd. The step of applying the second operation to this first number then comprises multiplying this first number with another integer greater than one, the result of which being then added with one.
[0012] Also, the function is selected so as to ensure that the function cannot “loop on itself”, meaning that for any starting first number, the function will always, after multiple iterations, converge to the same fixed number.
[0013] Alternatively, the method moreover comprises a step of verifying that the function is not looping on itself, e.g. through verifying that the second number was not already obtained in the pseudo-random sequence of numbers.
[0014] In the preferred embodiment described hereafter, first and second operations are defined as follows. In the first case, i.e. when first number is even, the step of applying the first operation to the first number further comprises dividing this first number by two. In the second case, I.e. when first number is odd, the step of applying the second operation to the first number further comprises multiplying this first number with three, the result of which being then added with one.
[0015] According to the preferred embodiment, the step of encyphering binary data, termed plain data, into encrypted binary data furthermore comprises the following steps: splitting the plain data into a sequence of consecutive binary words, termed word sequence, of a length based on a second key data; generating a sequence of numbers, termed encrypted sequence, from this word sequence, where at least one binary word from this word sequence is replaced with an number representing at least one position containing this binary word within the pseudo-random binary sequence; generating this encrypted binary data from this encrypted sequence.
[0016] In the reverse way, the step of decyphering encrypted binary data into decrypted binary data furthermore comprises the following steps: reading this encrypted data into a sequence of numbers, termed encrypted sequence; generating a sequence of binary data words, termed word sequence, from this encrypted sequence, where at least one number of this encrypted sequence is used as an offset for reading, whithin the pseudo-random binary sequence, a binary word the length of which is based on a second key data, this number of this encrypted sequence being replaced with this binary word into this word sequence; concatenating this word sequence into decrypted data.
[0017] A computerized device or system is also provided in embodiments of the invention, implementing such encrypting and/or decrypting method into software processing processor, or hardware or mixed circuits. Embodiments of the invention also provide a computer program the instructions of which carry out the steps of such a method, when this computer program is executed on a computer system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The new and inventive features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative detailed embodiment when read in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 schematically illustrates the progress of an encrypting process according to the invention;
[0020] FIG. 2 schematically illustrates the progress of a decrypting process according to the invention;
[0021] FIG. 3 is a block diagram illustrating an encrypted data transmission method between an emitter and a receiver, according to the invention;
[0022] FIG. 4 is a diagram illustrating the pseudo-random sequence of numbers for an example starting number value of 27, according to the preferred embodiment of the invention;
[0023] FIG. 5 is a table showing the distribution pattern of available offsets, for all possible word values with an example word length value of 4 bits, for the 64 first starting numbers which enable all such values, according to the preferred embodiment of the invention;
[0024] FIG. 6 is a table showing the distribution pattern of available offsets, for a binary word with an example value of 14, among the 64 first starting numbers which enable all values of binary words with an example length of 4 bits;
[0025] FIG. 7 is an histogram showing the distribution of the number of possible starting numbers for ciphering the example binary word of FIG. 6 , among the same 64 first starting numbers.
[0026] In the following specifications, elements common to several figures are referenced through a common identifier.
DETAILED DESCRIPTION OF THE INVENTION
[0027] A preferred embodiment of the invention is based on a pseudo-random sequence generated by a function of a Collatz type.
Collatz Functions
[0028] The original Collatz function is defined as follows:
[0000] Consider the following operation on an arbitrary positive integer:
[0029] If the number is even, divide it by two.
[0030] If the number is odd, triple it and add one.
[0031] For example, if this operation is performed on 3, the result is 10; if it is performed on 28, the result is 14. There is an unsolved conjecture in mathematics, based on this function, called the Collatz conjecture. It is named after Lothar Collatz, who first proposed it in 1937. This conjecture is also known as the “3n+1” conjecture, the Ulam conjecture (after Stanislaw Ulam), or the Syracuse problem. This conjecture asks whether a sequence based on the Collatz function, or a certain kind of number sequence, always ends in the same way regardless of the starting number. Paul Erdos said about the Collatz conjecture: “Mathematics is not yet ready for such problems.” He offered $500 for its solution.
[0032] In mathematical notation, we can define the Syracuse (or Collatz) function “S” in its original form as follows:
[0000]
S
(
n
)
=
{
n
2
,
if
n
≡
0
[
2
]
3
×
n
+
1
,
if
n
≡
1
[
2
]
[0033] Starting with an initial number S 0 , it is possible to generate the sequence of “Syracused Numbers” as defined below, until the value 1 is reached:
[0000] SN 0 =S 0
[0000] SN i+1 =S ( SN i )
[0034] In the Syracuse conjecture literature, the following jargon is usually adopted:
This sequence {SN i } is known as the flight of S. Each SN i is a stage of the flight. The highest SN i is known as the maximal elevation of the flight. The duration of the flight is the number of stages before reaching the value 1. The flight in elevation is the number of stages before going under the initial value S 0 .
[0040] The expansion factor is the ratio between the maximal elevation and the starting value S 0 .
[0041] Some examples of sequence characteristics for the original Syracuse/Collatz function:
[0000]
Flight
in
ele-
dura-
va-
Expansion
S 0
tion
tion
Maximal elevation
factor
7
16
11
52
7.43
32
5
1
32
1
27
111
96
9232
341.93
97
118
3
9232
95.18
2 50 + 1
332
3
3377699720527876
3
871
178
57
190996
219.28
703
170
132
250504
356.34
100759293214567
1820
166
1180174841128253392
11712.81
[0042] This original function may be generalized into a type of functions called Collatz type. A function G is called an Collatz type function if there is an integer n together with rational numbers {a i : i<n}, {b i : i<n} such that:
[0043] whenever x≅i mod p
[0044] then G(x)=a i x+b i is integral.
[0045] The method according to the invention uses a function of Collatz type for generating the pseudo-random sequence of numbers. In a preferred embodiment described hereafter, the following Collatz type function is chosen for generating a pseudo-random sequence of numbers.
[0000]
s
(
n
)
=
{
n
2
,
if
n
≡
0
[
2
]
3
×
n
+
1
2
,
if
n
≡
1
[
2
]
[0046] Some examples of sequence characteristics for this modified Syracuse/Collatz function, as used in the preferred embodiment described hereafter:
[0000]
Flight
S 0
duration
in elevation
Maximal elevation
Expansion factor
7
11
6
26
3.71
32
5
1
32
1
27
70
59
4616
170.96
97
75
1
4616
47.59
871
113
34
95498
109.64
703
108
80
125252
178.17
[0047] Applicant assumes that the Syracuse conjecture is true. However, even in the opposite case, such functions nevertheless provide various pseudo-random sequences that are sufficiently numerous for building an encrypting/decrypting method with a good trade-off between security and power or speed performances. FIG. 1 and FIG. 2 respectively illustrate encrypting and decrypting of binary data according to the invention. In FIG. 1 , a starting number S 0 110 is used as a secret key for encrypting plain binary data 114 comprising a sequence {bi} of binary bits. This starting number 110 is used as an initial first number for generating 121 and memorizing a pseudo-random sequence of numbers {si} 112 , through iteration of the pseudo-random function. The generated pseudo-random sequence 112 of numbers is then processed through a conversion treatment 122 , resulting into a pseudo-random sequence 113 of binary digits {sbi}
[0048] Preferably, the conversion treatment 122 comprises the following steps:
[0049] if said second number is greater than said first number, adding to the binary pseudo-random sequence a binary digit of a type, e.g. a bit with value “one”; or
[0050] if said second number is lesser than said first number, adding to the binary pseudo-random sequence a binary digit of the other type, e.g. a bit with value “zero”.
[0051] The resulting binary pseudo-random binary sequence 113 is then used as a seed for encyphering a sequence {bi} of binary data 114 , termed plain data, into a encrypted sequence {cbi} of binary data 117 .
[0052] This encyphering process comprises the following steps. Plain data 114 is converted 123 into a sequence 115 of consecutive binary words, termed word sequence{wi}, these words being of a length L based on a second key data 111 . This second key data may be used as a second secret key, possibly transmitted or detained separately from a first secret key based on the starting number 110 . The first 110 and second 111 key data may also be united or combined to form a unique secret key, which then need to be separated before use.
[0053] From this word sequence 115 , a encrypted sequence 116 of numbers {ni} is generated 124 through replacing each binary word w i with a number n i representing one position containing said binary word within the pseudo-random binary sequence 113 . The encrypted sequence of number 116 is then converted 125 into a sequence {cbi} of binary data 117 , providing the encrypted data 117 issued from the initial plain data 114 .
[0054] In FIG. 2 , a starting number S 0 210 is used as a secret key for decrypting a encrypted binary data 214 comprising a sequence {cbi} of binary bits. In a manner that may be the same as in FIG. 1 , a pseudo-random binary sequence 213 is generated 221 , 222 from the same starting number 210 , which was once used for producing this encrypted binary data 214 . The resulting binary pseudo-random binary sequence 213 is then used for decyphering a sequence {cbi} of binary data 214 , termed encrypted data, into a plain sequence {bi} of binary data 217 .
[0055] The decyphering process comprises comes as follows. The encrypted data 214 is read 223 into a sequence of numbers {ni}, termed encrypted sequence 215 . A sequence of binary data words {wi}, termed word sequence 216 is generated 224 from the encrypted binary sequence 213 . Each number from this encrypted sequence of numbers 215 is used as an offset for selecting a reading position within the pseudo-random binary sequence 213 . Starting from this reading position, a binary word is read of a length L corresponding to the same second key data 211 , which was once used for producing this encrypted binary data 214 .
[0056] All the binary words of the resulting word sequence 216 are then concatenated 225 into a sequence of binary data {bi}, termed decrypted data 217 , which is then identical to the binary data that was once used for producing the encrypted binary data 214 . Although such ciphering and deciphering algorithm provides a good optimization when combined with pseudo-random sequences defined above, different algorithms may also be used for ciphering and deciphering plain data based on using such a pseudo-random binary sequence.
[0057] FIG. 3 illustrates more specifically a transmitting process of binary data 300 between an emitting device 301 and a receiving device 302 . Two parties “A” 301 and “B” 302 need to exchange a binary information 300 in a secret way. The following assumptions are made and the following notations are used in the rest of this example:
Both parties A and B know 309 a secret key S 0 . Both parties A and B know 309 a secret length L. The binary information 300 to be shared from A to B is represented by a sequences of N bits {b i } i=1 i=N . N is a multiple of L The proposed method for ciphering the binary information is based on the following steps: In an initialisation stage 307 , both parties A 301 and B 302 build ( 312 , respectively 322 ) build the binary pseudo-random sequence {s i }defined by:
[0000]
s
i
=
{
1
,
if
s
(
n
)
>
s
(
n
-
1
)
0
,
if
s
(
n
)
<
s
(
n
-
1
)
[0062] In its binary form {s i }, this sequence specifies the behavior of the Syracuse suite: does it go up (bit at “1”) or down (bit at “0”) at each successive step? For each plain data 300 they wish to share, emission from A 301 to B 302 comprises the following steps:
[0063] The A party 301 splits 313 the plain text {b i } i=1 i=N 300 as a sequence of words {w j } j=1 j=N/L , defined as:
[0000] w i ={b i } i=(j−1)×L+1 i=j×L .
[0064] For each word w j , the A party searches 314 in the sequence {s i } a series of L successive bits starting with offset n j such that: w j ={s i } i=n j i=n j +L−1 . If multiple solutions exist, the A party takes any of them in any way, possibly using a random or pseudo-random selection.
[0065] The A party sends 315 to the B party 302 the series {n j } i=1 i=N/L representing the genuine information {b i } i=1 i=N 300 , enciphered by the “Syracuse Secret Key” S 0 .
[0066] The B party 302 receives 323 the series {n j } i=1 i=N/L from the A party.
[0067] For each offset n j , the B party reconstructs 324 each word w j ={s i } i=n j i=n j +L−1 .
[0068] From the sequence of words {w j } j=1 j=n/L , the B party reconstructs 325 the original information {b i } i=1 i=N 300 .
[0069] These steps can be implemented in various ways (hardware, software, hybrid), all following the logic described in the diagram of FIG. 3 .
[0070] A person skilled in the art will easily understand that the proposed method and system asks for very few IT resources for its implementation. The required processing power is very low (simple operations like additions and shifts are needed), and the required memory is also very low (several bytes of ROM memory and few bytes of RAM memory are needed).
Example of a Data Transmission
[0071] The secret first key 110 , 210 of a value S 0 =27 is secretly known by both parties A 301 and B 302 . FIG. 4 shows the flight corresponding to the pseudo-random sequence 112 , 212 generated for this value of “27” for the secret key.
[0072] The same pseudo-random binary sequence 113 , 213 built by both parties A and B may be written as:
[0000] {s i }={1101111101011011101111010011101101111110011110001010100010011100001001}.
[0073] The secret second key 111 , 211 of a value L=4 is known by both parties A and B, is used as a length for the words w i of the word sequence 115 .
[0074] In this example, the genuine information 300 , 114 that party A wants to transmit to party B under a encrypted form is defined as:
[0000] {b i } i=1 i=N ={1011111110101011011011011001101011011101}.
[0075] This genuine length N=40 is known by A. Thus, the party A splits 123 this information 300 , 114 into a sequence 115 of ten words, each of 4 bits. Each word is then encrypted according to the pseudo-random binary sequence 113 .
[0076] The party A performs the following operations:
w 1 ={1011}, so that n 1 ε{2, 10, 13, 17, 29, 32}; the value n 1 =17 is randomly selected. w 2 ={1111}, so that n 2 ε{4, 5, 19, 34, 35, 36, 42}; the value n 2 =5 is randomly selected. w 3 ={1010} so that n 3 ε{8, 22, 49, 51}; the value n 3 =8 is randomly selected. w 4 ={1011} so that n 4 ε{2, 10, 13, 17, 29, 32}; the value n 4 =10 is randomly selected. w 5 ={0110} so that n 5 ε{11, 30}; the value n 5 =11 is randomly selected. w 6 ={1101} so that n 6 ε{1, 7, 12, 16, 21, 28, 31}; the value n 6 =16 is randomly selected. w 7 ={1001} so that n 7 ε{24, 39, 57, 67}; the value n 7 =24 is randomly selected. w 8 ={1010} so that n 8 ε{8, 22, 49, 51}; the value n8=8 is randomly selected. w 9 ={1101} so that n 9 ε{1, 7, 12, 16, 21, 28, 31}; the value n 9 =31 is randomly selected. w 10 ={1101} so that n 10 ε{1, 7, 12, 16, 21, 28, 31}; the value n 10 =12 is randomly selected.
[0087] Thus, the ciphered information {ni} 116 sent, e.g. under a standard binary form, from A to B is:
[0000] {n j } i=1 i=N/L ={17, 5, 8, 10, 11, 16, 24, 8, 31, 12}.
[0088] B party receives this sequence, e.g. under its binary form, and uses it as a sequence 215 of offsets for generating the plain binary data 217 . Thus, the party B applies each number of the encrypted sequence {n j } i=1 i=N/L 215 to the binary form 113 , 213 of the pseudo random sequence {s i } 112 , 212 , for deriving the sequence of words {w j } j=1 j=N/L 216 . Concatenation of the binary words from this word sequence 216 thus provides a binary sequence 217 identical to the genuine information 300 , 114 :
[0000] {b i } i=1 i=N ={1011111110101011011011011001101011011101}.
[0089] Assume that a third party C wants to break the ciphered information, but ignoring both the secret key S 0 and the secret length L. This third party C assumes that the secret key is equal to 91 (wrong choice) and that the secret key is equal to 4 (right choice). Under these assumptions, we have for the party C:
S 0 =91 {s i }={11011101111010011101101111110011110001010100010011100001001}
the value n 1 =17 gives w 1 ={1101}, the value n 2 =5 gives w 2 ={1101}, the value n 3 =8 gives w 3 ={ 1111 }; the value n 4 =10 gives w 4 ={ 1101 }; the value n 5 =11 gives w 5 ={1010}; the value n 6 =16 gives w 6 ={1110}; the value n 7 =24 gives w 7 ={1111}; the value n 8 =8 gives w 8 ={1111}; the value n 9=31 gives w 9 ={1111}; the value n 10 =12 gives w 10 ={0100} The resulting deciphered information is:
{1 10 111 0 11 1 1 1 1 10 1 10 1011 10 1 11 11 1 1 1 11 1 1 0 10 0 }
[0102] where underscored digits are wrong (18 out of 40).
[0103] Thus it can be seen that the ciphered information 117 , 214 is indeed a encrypted form af the genuine plain data 114 , 217 .
[0104] According to selected combinations of length L and starting number S 0 , strength and flexibility of the encryption may vary. Flexibility must be sufficient for encryption of the genuine data intended to be transmitted, i.e. each binary word to be encrypted 115 must be found at least once under its binary form within the generated 122 binary pseudo-random sequence 113 . Furthermore, when only one offset exists for such a word, breaking the code may be easier than if several offsets are possible.
[0105] FIG. 5 to FIG. 7 illustrates an example of distribution for the coding possibilities for a word length L of 4 bits. A 4 bits-word may takes 72 different values, ranging from {0000} to {1111}.
[0106] Within the pseudo-random binary sequence generated from an integer taken as starting number, it is not always possible to find an offset with every combination of such a 4 bits-word. The more long the word, the harder it becomes. Thus, only a part of the possible keys S 0 enable to code any value of such a word. Such keys may be termed “full keys”, for a given word length.
[0107] FIG. 5 is a table showing a distribution pattern of available offsets, for all possible word values with length value of 4 bits. This table shows the 64 first starting numbers which may be used as full keys for such a word. The top title line 501 shows the values of these 64 first full keys. All possible decimal value of a 4 bits binary word stand in the left title column 502 , while the total number of possible offset for each word value stands in the right column 503 .
[0108] For instance, starting number 27 results in a pseudo-random binary sequence which offers 7 different offsets corresponding to the word {1110}, i.e. with value 14 . Also, this word value 14 may be coded in 422 possibilities for the 64 first full keys.
[0109] It can be seen that numerous possibilities exist even for starting numbers quite low, thus enabling simple and compact computing or memorizing.
[0110] In the table of FIG. 6 , cells in grey show the distribution pattern of these 422 available offsets n i for the same 4-bits word value 14 . Offsets from 1 to 72 stand on the left title column 602 , while the starting numbers stand on the top title line 601 . For instance the offset pattern for the value SN 0 =27 (ref. 604 ) is equal to the set {6, 15, 20, 27, 37, 43, 60}.
[0111] On the right column 603 is reported, for each line, the number of starting numbers that may code this value 14 with the same offset. Thus, the value 14 coded at offset 6 (ref. 605 ) still leaves 8 (ref. 606 ) different possible keys among the 64 first full keys. These 8 possible keys are in the set {27, 82, 83, 103, 121, 194, 195, 233}.
[0112] In this specific example, it can be seen that different keys do not result in the same possible offsets, meaning that knowledge of the length and position of one specific word is usually not sufficient for retrieving the secret key. There are only a few similarities between different starting numbers. In this example, there are no more than 4 keys that have a similar distribution pattern (e.g. keys 193 , 194 , 195 , 199 ). Also, all the possible offset values (on the left) are more or less equally visited, as seen in FIG. 7 .
[0113] In FIG. 7 , offsets from 1 to 72 stand on the bottom line 701 , while each bar of the histogram 702 shows the number of possible starting numbers for ciphering the same binary word of value 14 , among the same 64 first full keys. This example is one among several simulations that gave similar results, thus indicating an interesting encryption performance when balanced with the low need in power or speed resources.
[0114] In a preferred embodiment, selection of any starting number as a key may be validated through checking that this starting number is indeed a full key for the word length selected.
[0115] While the invention has been particularly shown and described mainly with reference to a preferred embodiment, it will be understood that various changes in form and detail may be made therein without departing from the spirit, and scope of the invention. In other embodiments, for example, possibly combined with the preferred one, starting numbers may be selected as keys even if not a full key. The encrypting method may then comprise a step of changing this key into another, through an algorithm shared between parties, e.g. by automatically selecting the next full key when encountering a word with no available offset in the initial key. Such a key modification may also be triggered on a test issuing a strength quality too low for the selected key, for some words or for all of them. Such a strength quality evaluation may be based on a low number 608 of possible keys for a given word at a given offset 607 of the pseudo-random binary sequence 113 , 213 .
[0116] First and/or second operation may also be changed or modified, for the generation of the whole pseudo-random sequence or in the course of such a generation. Several pseudo-random sequences may also be used together, alternatively or interleaved.
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The present invention relates to the field of computer data encrypting and decrypting, especially for mobile equipments like PDA, mobile phones, smart cards and the like, which need a good trade-off between computing speed, power consumption and security strength. Embodiments of the invention provide encrypting/decrypting methods implementing simple data operation. Such methods are based on generating a pseudo-random sequence through a function of the Collatz (or Syracuse) family from a starting number used as a secret key.
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BACKGROUND OF THE INVENTION
The present invention relates to a valve comprising a valve body which forms a fluid channel or passage and an inner cavity having a geometrical axis being substantially normal to the axis of the fluid channel and provided with an opening located in a plane lying substantially normal to the geometrical axis, and further comprising closing means having a movable closing member and a support which accommodates the closing member and delimits a channel which is aligned with the fluid channel, the closing means being accommodated in the inner cavity by being inserted through said opening, and the support is mounted in the valve body with a connector means.
This type of valve is intended for use in an installation for gas or oil production, in particular in an underwater installation.
The closing means may be dismounted and the closing member also has a channel which can be displaced either by translation or by rotation between an "open" position in which the channel is aligned with said fluid channel in the support, and a "closed" position in which the channel in the closing member is not in correspondence with the fluid channel of the support.
European patent application 0132989 describes such a valve in which the connector device comprises a locking collar provided outside the valve body and comprises two halves which are pivotable about a fixed axis on the valve body. There is provided a circular groove in the inner surface of the collar. This groove is adapted to cooperate with a flange on the valve body and a support member so that the closing means is united with the valve body. At the opposite side in relation to the pivot axis the two collar halves are adapted to be connected to each other by means of attachement elements.
This connecting or locking system has several drawbacks. In the first place the movable parts of the connector device are carried by the valve body which is installed in a pipeline system in a non-dismountable manner, which is in turn located on the seabed. This means that a reduced function of the collar as a result of shocks occurring during mounting or retrieving of the movable closing means, may involve great difficulties in repairs and will necessitate long interruptions of the production at the installation. Besides, the movable elements which are located outside the valve, will be subject to the marine environment, which is highly corrosive. The pivot axis as well as the attachement elements are attacked by the seawater, possibly leading to functional problems. Finally, the connection and disconnection of the arrangement, which usually take place by means of a robot, necessarily involves several operations, namely on the attachement elements and swinging of both collar halves by rotation about the pivot axis.
OBJECTS AND SUMMARY OF THE INVENTION
The object of this invention is to provide a valve which avoids the drawbacks discussed above, in which the connector device is protected against the ambient environment, in which the valve body does not carry any movable connector element and for that reason does not require any particular maintenance, in which connection and disconnection take place by a simple translatory movement, and in which maintenance of the movable connector elements and verification of their correct function can be performed at the surface during periodic inspections of the closing means.
According to the invention this object attained whereby in the valve of the type stated above, the connector device comprises fixed elements provided in the interior of the inner cavity and movable elements provided at the support, and the connector device is protected in a sealed manner in relation to the ambient environment and to the fluid.
The fixed element comprises at least a rest which is formed in the valve body and which opens towards the cavity, and the movable elements comprise at least one locking piece mounted in the support and being radially movable in relation to said geometric axis under the influence of an actuating member, and can assume two extreme positions:
one position remote from the geometric axis, in which the locking piece extends partially into at least one of the rests so that the connection is secured, and
a position closer to the geometrical axis, in which the locking piece is located in the support so that insertion of the closing means in the inner cavity is possible.
As a result of this solution, the valve body has no movable connector element and the movable connector elements are integral with the movable closing means, which makes maintenance and inspection of these movable elements possible at the surface during periodic maintenance of the closing means.
According to a particular feature of the invention, each rest is in the form of a circular groove having the same geometric axis as the inner cavity. The locking pieces are formed by segments of an annulus which has an exterior surface adapted to the shape of the circular grooves. Rests or recesses for the locking pieces can therefore easily be provided and the locking pieces being in the form of annular segments having an outer surface adapted to the shape of the rests, secure a perfect mutual coupling of the valve body and the closing means when the latter is mounted in the inner cavity of the valve body.
According to another particular feature of the invention, the segments are mounted in a circular chamber provided in said support and being open towards the circular grooves. Each segment cooperates with a vertically movable cam element in such a way that an axial movement of the cam element, under the influence of the actuating member, provides for a radial displacement of the segment.
The surface of each segment situated adjacent the geometric axis of said cavity is inclined in relation to the geometric axis. The cam element slides along this surface as the cooperation is effected by means of a T-groove formed in one of the parts, i.e. the cam element or the segment, and by a T profile element received in the T-groove and provided on the other of the parts, i.e. either the segments or the cam element.
Each cam element is attached to the end of a rod which can be displaced in a bore provided in the support and which lies parallel to the geometrical axis. The rods attached at their opposite ends to a common ring located outside the valve, so that an axial movement of the common ring under the influence of the actuating member results in a simultaneous radial displacement of all the segments.
This design makes it possible to connect or disconnect the closing means by a simple translatory movement of a common ring located outside the closing means. A translatory movement of this common ring also enables possible inspection or verification of the movable connector elements from the surface.
According to still another particular feature of the invention, sealing elements or gaskets are carried by the support are provided between this support and the valve body at one and the other side of the connector device.
Other advantages and specific features of the invention will appear from the description of an embodiment given as an example and with reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a crossection of a valve according to an embodiment of the invention,
FIG. 2 is a crossection of the valve body of the valve of FIG. 1,
FIG. 3 is a crossection of the closing means of the valve of FIG. 1,
FIG. 4 is a crossection along the line IV--IV in FIG. 3,
FIG. 5 is a plan view of an annulus for which there are formed segments which constitute connecting or locking pieces for the valve of FIG. 1,
FIG. 6 is a crossection along the line VI--VI in FIG. 5,
FIG. 7 is a perspective view of a locking piece of the valve of FIG. 1,
FIG. 8 is a perspective view of a rod with a cam element,
FIG. 9 is a crossection along the line X--X in FIG. 8,
FIG. 10 shows the position of the connector device when a common ring is located in its lower position,
FIG. 11 shows the position of the same connector device when the common ring is located in its upper position, and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As seen from the drawings the valve 1 comprises a valve body 2 and a closing means 3 which is united with the valve body 2 by means of a connector device 4.
The valve body 2 is inserted into pipeline parts, not shown, by means of flanges 5a, 5b or any other known methods, for example by welding. The valve body 2 has an inner cavity 6 of generally truncated conical shape widening upwards and having an upper opening 7. The inner cavity 6 communicates with the upstream pipeline through a first channel 8a and with the downstream pipeline through another channel 8b. Channels 8a and 8b are mutually aligned and have a horizontal axis 10 which is substantially normal to the geometric axis 11 of the cavity 6. The cavity 6 is delimited by a bottom 12 opposite to the opening 7 and by a sidewall 13. Channels 8a and 8b are open into this cavity 6 at openings 14a and 14b. The channels 8a and 8b constitute a fluid passage 15 between an upstream pipeline and a downstream pipeline. The opening 7 in the cavity 6 is situated at a plane 7a which is substantially normal to the geometric axis 11.
The closing means 3 is adapted to be inserted into the inner cavity 6 through the opening 7. In order to facilitate the insertion of the closing means 3 into the cavity 6, the geometric axis 11 of the cavity 6 preferably is vertical.
The closing means 3 comprises a support 16 which has an exterior side wall 17 which is generally shaped as a truncated cone and is adapted to generally match the shape of the side wall 13 of the cavity 6, and a closing member 18 is movably mounted in the interior of the support 16. The support 16 is provided with channels 19a, 19b and the closing member 18 has a channel 20 so located that the first channel 8a in the valve body 2 can be put into communication with or blocked from the second channel 8b in the valve body 2.
In the embodiment shown in the drawings the closing member 18 consists of a spherical ball body 22 provided with a horizontal channel 20 and adapted to be rotated about a vertical axle 23 which is connected to the valve ball 22. The support 16 has an interior spherical cavity 24 adapted to match the shape of the ball body 22, a vertical bore 25 in which the axle 23 can be rotated, and horizontal channels 19a and 19b which are aligned with respect to the channels 8 and 9 in the valve body 2. The closing member 18 can be moved by an actuator unit 26 mounted at the upper part 27 of the support 16 and adapted to rotate the axle 23 in such a way that the ball body 22 can assume two positions:
A first position in which the horizontal channel 20 in the ball body 22 is aligned with the channels 19a and 19b in the support 16 and the fluid can flow from the upstream pipeline to the downstream pipeline through the fluid passage 15, and a second position obtained by rotating the axle 23 through 90° under the influence of the actuator unit 26, in which the wall of the ball body 22 blocks the channels 19a and 19b in the support 16 and thereby passage of fluid between the upstream pipeline and the downstream pipeline. The channels 19a and 19b define a fluid channel 21 in the closing member 3.
The axis 10 is also the axis of the fluid channel 21, and this axis intersects the geometric axis 11 of the inner cavity 6 at a point O 1 which is the center of the spherical cavity 24 and of the ball body 22. The axis of the rotation axle 23 is the geometric axis 11 which is likewise the geometric axis of the closing means 4 and the support 16.
In order to facilitate the introduction of the closing means 4 into the valve body 2 and to ensure alignment of the channels 19a and 19b in the support 16 with respect to the channels 8a and 8b in the valve body 2, the valve body comprises supplementary exteior wall elements 28 having vertical holes 29, and the support 16 comprises wall elements 30 corresponding to the supplementary wall elements 28 and provided with vertical guide pins 31 adapted to the holes 29.
During operation, the closing means 3 is joined to the valve body 2 by means of a connector device 4 comprising fixed elements and movable elements.
For this purpose, a circular part 35 of the wall 13 in the valve body 2, located adjacent the opening 7 to the valve body, is provided with rests or recesses 36 being open to the interior of the cavity 6 of the valve body 2.
Locking pieces 37 are mounted on support 16 and are movable radially in relation to the geometric axis 11 and being able to assume to extreme positions:
A first position in which each locking piece 37 is remote from the rests 36 and retracted into a chamber 38 in the support 16 so that insertion of the closing means 3 into the inner cavity 6 is permitted, or alternatively removal of the closing means 3 from this cavity 6, and another position in which projections 39 on each locking piece 37 are moved away from the geometric axis 11 and enter into a rest 36 so that the closing means 3 is connected to the valve body 2. The chambers 38 are formed in the exterior side wall of the support 16 and are open to the outside thereof and are located adjacent the rests 36 when the closing means 3 have been correctly installed in the valve body 2.
As shown in the drawings, the rests 36 consist of three circular grooves 36a the axis of which is the geometric axis 11 of the cavity 6 and the locking pieces 37 can all be retracted into the same chamber 38, which consists of a circular recess 40 the axis of which is the geometric axis 11 of the cavity 6 and with a horizontal upper wall 41 and lower wall 42.
The circular recess 40 comminicates with the upper surface 43 of the support 16 through vertical bores, in each of which there can slide a rod 44 which is extended above the upper surface 43. Each bore 44 is extended below the lower surface 42 of the circular recess 40 in the form of a bottom bore 46. The upper ends 47 of the rods 45 are attached to a ring 48 which is vertically movable. At the lower end 49 of each rod 45 there is mounted a cam element which is vertically movable together with the rod 45.
The side 51 of the cam element which faces away from the geometric axis 11 is designed with a crossectional profile 52 of T shape, which can slide in a T groove 53 formed in a surface 54 at one of the locking pieces 37 facing towards the geometric axis 11. The surface 54 of the locking piece 37 is inclined downwards and against the geometric axis 11 and has a general direction which forms an angle of approximately 6° with the geometric axis 11. The T groove 53 is parallel to the surface 54 and extends from below and upwards along the whole thickness of the locking piece 37. The locking pieces 37 consist of segments 55 of an annular ring 56 the outer surface 57 of which is exactly matched to the shape of the circular part 35 of the wall 13 in the valve body 2, and the projections 35 on the locking pieces are in the form of teeth 58 the upper surface 59 of each of which is inclined upwards and against the inner cavity 6, thereby forming an angle of between 0° and 30° with the horizontal, whereas the lower surface 60 is inclined downwards and inwards towards the cavity 6 and also forms an angle of between 0° and 30° with the horizontal. This choice of angles of the upper surface 59 and the lower surface 60 in relation to the horizontal, makes it possible to avoid adhesion or wedging of the teeth 58 of the circular grooves 36a.
The outer diameter of the ring 56 is equal to the diameter of the circular grooves 36a. In the exampel shown in the drawings the number of segments 55 being formed from a ring 56, is equal to 10, but this number apparently can be higher or lower than 10. The dimension of each segment 56 in the circumferential direction is calculated in such a manner that the locking pieces 37 can be displaced radially without interfering with each other.
Because the T groove 53 forms an angle of approximately 6° with the vertical, it will easily be seen that when the cam element 50 is moved vertically, the profile 52 slides in the groove 53 and brings about a radial displacement of the locking pieces 37.
The ring 48 is adapted to be moved vertically be means of an actuating device not shown, for example a hydraulic cylinder, between two extreme positions:
An upper position (FIG. 11) in which the ring 48 is removed from the upper surface 43 of the support 16, which involves a positioning of the locking pieces 37 in the circular recesses 40, whereby the teeth 58 are located in the chamber delimited by the upper wall 41 and the lower wall 42 in the recess 40, and a lower position (FIG. 10) in which the ring 48 is located adjacent the upper surface 43 of the support 16, which brings the projections 39 on the locking pieces 37 to leave the circular recess 40 and enter into the grooves 36a.
The upper end 62 of the wall 13 in the inner cavity 6 has a widened shape, and the support 16 has a wall portion 63 matching the shape 62 of the upper wall and carries a seal 64 so that there will be a complete sealing of the cavity 6 when the closing means 3 is mounted in the cavity 6. A seal 65 is provided between the wall 13 and the valve body 2 and the wall 17 of the support 16. This seal or gasket is mounted in a circular groove 66 formed in the wall 17 between the connector device 4 and the lateral openings 67a, 67b for channels 19a and 19b. A seal 68 is also located between the vertical bores 44 and the rods 45.
The connector device 4 is protected against the environment by means of the seal 64 and the seals 68 and is moreover protected against the fluid flowing in the passage 21 by means of the seal 65.
The anchoring arrangement has a function to be described as follows:
Before the closing means is inserted into the valve body 2 through the opening 7, the ring 48 is placed in its upper position under the influence of the actuating device which can be a hydraulic cylinder, for example. The closing means 3 can then be introduced into the cavity 6. Then the hydraulic cylinder is actuated so as to move the ring 48 to its lower position, which results in the rods 45 and the cam elements 50 being moved downwards, the lower portion 61 of the cam elements entering into the bottom bores 46 and the locking pieces 37 partly protruding out of the support 16, and the teeth 58 will then come into contact with the wall in the circular grooves 36a.
In order to retract the closing means 3 from the valve body 2, the operation is effected in the inverse manner. It is sufficient to put the ring 48 in its upper position in order to release the closing means 3 from the valve body 2.
Locking or disconnection of the closing means is effected by a simple translatory movement of the ring 48. This elementary movement can be provided for by a robot.
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This invention relates to a valve comprising a valve body and a dismountable closing means. The closing means comprises a closing member and a support which carries the closing member is received in an inner cavity in the valve body. Locking of the closing means in the inner cavity is ensured by means of circular grooves formed in a side wall of the cavity, and movable locking pieces carried by the support and cooperating with an exterior ring via can elements. Axial movement of the ring results in a radial displacement of the locking pieces and thereby permitting insertion and removal of said closing means into and out of said valve body.
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This invention generally relates to fluid flow control devices and in particular to actuators for fluid flow valves.
BACKGROUND OF THE INVENTION
A variety of fluid flow control valves and corresponding valve actuators are utilized for on/off control or throttling the flow of fluid, such as in a gas or oil pipeline system, or in other process fluid systems. The fluid flow control valves are typically sliding stem control valves or rotary action control valves and are operated by a valve actuator such as a pneumatic piston or diaphragm actuator responding to the output of a valve positioner or valve controller instrument for accurate throttling control of the valve.
For example, typically the fluid control valve is mounted in the pipeline system with a pneumatic actuator mounted on top of a fluid control valve and coupled to the valve fluid control element, such as a sliding stem or rotary shaft. If utilized, a valve positioner or valve controller instrument is mounted to the side of or above the actuator utilizing suitable mounting brackets and pneumatic tubing is provided between the pneumatic output of the positioner and the pneumatic input of the valve actuator. Thus, the overall valve, actuator and positioner assembly can be a fairly large and heavy combination of elements extending for some distance above the valve and projecting therefor above and to the side of the pipeline and possibly greatly beyond the valve itself.
With reference to my U.S. Pat. No. 5,487,527, "Valve Actuator", assigned to the same assignee as herein, there is provided a valve actuator for fluid control valves with a reversible power module having a stationery inner member and a coaxial aligned movable outer member coupled to a valve flow control element and slidably movable on the inner member. A chamber is formed between respective ends of the inner and outer members. Pneumatic pressure applied to the chamber drives the movable member to actuate the valve in a first direction and a spring returns the movable member in a second direction. In one embodiment, a balloon-type bladder is inserted in the chamber formed between respective ends of the members so that upon the coupling of suitable fluid pressure to the bladder inlet, the movable outer member will be moved by the expanding bladder trapped between the fixed inner member and the movable outer member.
While the bladder embodiment shown in my aforementioned patent performed satisfactorily at ambient temperatures, the unit was found not to perform satisfactorily under a variety of temperatures. In addition, it is desired to provide the valve actuator with a bladder device which exhibits commercially acceptable reliability characteristics, particularly over extended operating cycles and wide temperature and pressure ranges.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, there is provided an actuator which includes a bladder-type device which is preformed into the shape of a defined chamber between a fixed inner actuator member and a movable outer actuator member in the smallest defined chamber configuration. It has been found that in order to provide the most reliable bladder operation over a variety of temperature conditions and to decrease bladder wear, the bladder also must be preformed in the natural state to the smallest chamber size between the actuator members, so that the bladder material at the inside diameter will move to the outside diameter as the actuator is operated. This tends to always maintain the bladder material under tension so that the bladder perimeter will roll outwardly as the bladder is expanding within the chamber, in a rolling diaphragm action thereby reducing bladder wear.
It also has been found that to enhance the life and therefore the reliability of the bladder, after the bladder is formed, it must be stress relieved. Stress relieving of the bladder is obtained by baking the preformed bladder in an oven at about 250° F. for about 24 hours. It is believed that such stress relieving rearranges the molecular structure of the bladder material and thereby enhances the bladder life at cold temperature.
It is preferred to form the bladder material of polyurethane in a two-piece heat sealed structure. It further has been found to be desirable to provide a cloth reinforcing layer, such as a cloth backing on the polyurethane. At elevated high operating temperatures a thermopolyester plastic material such as Riteflex has been found useful for the bladder.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the several figures and in which:
FIG. 1 is an exploded perspective view illustrating a valve actuator, a valve positioning instrument, a feedback linkage mechanism, and a cover with respect to a valve actuator and control valve positioning instrument combination in accordance with the principles of the present invention;
FIG. 2 is an exploded view illustrating the actuator of the present invention with a reversible power module and yoke components;
FIG. 3 is an elevational view partly in section illustrating the actuator of FIG. 1 including a bladder-type device with an actuator movable outer member being spring-driven movably downwardly with respect to a stationery inner member;
FIG. 4 is an elevational view partly in section illustrating the valve actuator of FIG. 1 with the actuator movable outer member being movably driven upwardly with respect to a stationary member;
FIG. 5 is a sectional view taken along section line 5--5 of FIG. 6 illustrating a preformed bladder for location between the movable outer member and the stationary inner member;
FIG. 6 is a plan view of the bladder of FIG. 5 illustrating the two bladder inlets;
FIG. 7 is a fragmented sectional view illustrating a bladder inlet coupled to an actuator fluid inlet port; and
FIG. 8 is a fragmented sectional view illustrating a guide ring utilized for slidable guiding engagement between the stationary inner member and the movable outer member.
DETAILED DESCRIPTION
Referring initially to FIGS. 1 and 2, the present invention will be described with respect to a valve actuator 10 which includes a mounting pad 12 in the form of a ring for mounting of a valve positioner instrument 14. A feedback linkage mechanism 16 interconnects the actuator 10 and the valve positioner instrument 14. A cover 18 is provided for removable mounting on the actuator 10 so that the cover 18 preferably completely covers the feedback linkage 16.
A pneumatic output port 20 on the valve positioner 14 is mounted in line with an input port 22 on the mounting pad 12 at an instrument mounting position 24 with an o-ring 26 therebetween. The positioner 14 is then securely mounted on the mounting pad 12 at the mounting position 24 by suitable threaded means such as a pair of cap screws (not shown).
The actuator 10 includes a power module assembly 28 which is mounted by threaded screws (not shown) to a yoke 30. The valve actuator 10 is illustrated as coupled to a mechanical control element such as stem 32 for controlling for instance a fluid control valve 34, such as a sliding stem valve mounted in a pipeline 36. The combined actuator and instrument mounts to a valve bonnet 38 of the control valve 34, with the actuator yoke 30 held in place by a suitable lock nut threadably engaged on the bonnet 38 and threaded until locking against a yoke bottom flange 40.
The valve positioning instrument 14 can be a digital valve controller, such as a communicating, microprocessor-based current to pneumatic instrument. In addition to the normal function of converting an input current signal to a pneumatic output pressure, the digital valve controller, using a communications protocol, can provide easy access to information critical to process operation. Thus, one can gain information from the principle component of the process, i.e. the control valve 34, using a compatible communicating device at the control valve or at a field junction box, or by using a personal computer or operator's console within a control room. Alternatively, the instrument can be an analog device or a pneumatic positioner.
The feedback linkage 16 includes one end 42 engaging a pivoting bracket 44 on the positioner 14, whereas another feedback linkage end 46 is securely mounted to an actuator movable member 48. Because the actuator movable member 48 is interconnected with the valve stem or control element 32, the position of the valve stem is sensed by the positioner 14 through the feedback linkage mechanism 16.
Referring also now to FIGS. 3-8, there is illustrated the further details of a valve actuator having a preformed bladder in accordance with the present invention to provide reliable valve actuator operation over extended temperature and fluid pressure conditions. The power module 28 includes a stationary inner member 50 with lateral extensions 52, 54 integrally formed with the ring-shaped mounting pad 12, which mounting pad includes respective instrument mounting positions 24, 25. The mounting pad 12 is assembled on a mounting flange 56 of the yoke 30 by means of a series of suitable cap screws 57.
The stationary inner member 50 of the power module 28 is in the form of a stationary piston with an opened bottom end 58 as shown in FIG. 3 and an opposite closed top end provided by an end wall 60. The end wall 60 of the stationary inner member 50 extends between opposite points on a cylindrical-shaped perimeter side wall 62, i.e., the end wall 60 extends from reference points 60a to 60b as shown in FIG. 3. As shown in FIG. 3, the end wall 60 is step-shaped in cross-section, having three substantially parallel, horizontal end wall portions 64, 66, 68 joined by respective connecting slanting or vertical end wall portions.
The power module 28 also includes the movable outer member 48 in the form of a cylindrical canister axially aligned with and surrounding the stationary inner member 50. The movable outer member 48 includes opposite cavity/dome-shaped caps 70, 72 with the top cap 70 forming a dome-shaped end wall 74 which substantially matches the shape of the end wall 60 of the stationary inner member 50. The outer member 48 also includes a cylindrical side wall 73 adjacent and surrounding the inner member side wall 62 to define an annular perimeter space 75 therebetween. A stem connector plate 76 is welded to the bottom cap 72 and includes a central aperture for receiving the valve stem 32.
A guide ring 78 is mounted within an annular cavity 80 within the outer surface at the bottom end 58 of the stationary inner member 50 so as to be in sliding engagement against an inner surface 82 of the movable outer member 48. As shown most clearly in FIG. 8, the guide ring 78 includes a flat sliding surface 83 for slidably engaging the inner surface 82 of the outer member. The guide ring 78 is preferably formed of an elastomeric resin for low sliding friction, such as Delron. The purpose of the guide ring 78 is to enable guided movement of the movable outer member 48 with respect to the stationary inner member 50 and between the two extreme positions shown in FIGS. 3 and 4. In FIG. 3 it may be seen that the movable outer member 48 is substantially in the lower-most down position where a ledge 84 butts against a threaded stop 86. In contrast, in FIG. 4, the movable outer member 48 has been actuated and slidable moved upwardly under the guidable engagement of the guide ring 78 until a ledge 88 engages the threaded stop 86.
Within a chamber 90 defined between the stationary inner member end wall 60 and the movable outer member end wall 74, there is provided a sealed, preformed bladder 92 formed of two pieces joined by heat sealing at a joint 94. Bladder top-piece 92a is preformed to the shape of dome-shaped top end wall 74, and bladder bottom-piece 92b is preformed to the shape of the step-shaped bottom end wall 60. The bladder is formed of polyurethane with a cloth backing layer 95. For lower temperature usage the cloth backing layer 95 is not required. The cloth backing layer 95 surrounds the entire bladder 92 and serves to reinforce the bladder material for use at high operating temperatures. At extreme upper temperatures, a thermopolyester plastic material such as Riteflex may be used for the bladder, with or without a cloth reinforcing layer.
The bladder 92 is preferably preformed in the natural state to the smallest chamber size between the actuator members as shown in FIG. 3. Note from FIG. 3 that a bladder annular perimeter portion 93 is formed so as to extend within the annular perimeter space 75 and between the joint 94 and the reference points 60a, 60b. The cloth reinforcing layer 95 can be placed on the exterior surfaces of the bladder 92 by insertion during injection mold forming of the bladder. Alternatively, after injection molding of the bladder, the cloth can be applied thereto by suitable pressure and temperature conditions. A urethane layer can be used on a bias cut cloth prior to heat bonding to the bladder at a temperature of about 330° F. (166° C.) at 50 psi (345 Kpa) for about 1-1/2 hours. Instead of applying the cloth layer 95 on the entire bladder exterior, the cloth may be applied only to the annular perimeter portion 93 (see FIG. 7).
The cloth reinforced, preformed bladder is then baked in an oven to stress relieve the material. It has been found that such stress relieving of the bladder 92 in an oven can be accomplished at about 250° F. (121° C.) for about 24 hours.
To keep the bladder in place during actuator operation, upon assembly into the actuator, bonding adhesive beads may be applied above and below the joint 94 at the actuator movable member 48. Similarly the bladder can be bonded with a suitable adhesive to the top of the end wall 60.
The bladder 92 includes two respective inlets 96, 98. The stationary inner member 50 includes an inner member wall 100 which includes a passageway 102 which communicates with the input port 22, at the mounting pad 12 through a connecting passageway 104 in the lateral extension 52. Similar manifold passageways through the actuator are provided on opposite sides of the power module 28 and through the lateral extension 54 leading to an input port 106 at the instrument mounting position 25 (See FIG. 2). FIG. 7 illustrates a large plug 108 inserted into passageway 104 when the instrument 14 is mounted at the mounting position 24. In such a configuration, a small plug (not shown) would be inserted into a passageway (similar to passageway 104) in the lateral extension 54 so as to prevent fluid escaping from that passageway through the input port at the unused instrument mounting position 25.
As shown in FIG. 7, the bladder inlet 96 is coupled to the passageway 102 using an extended pilot tube 110. This permits fluid communication between the pneumatic output port 20 of the valve controller instrument 14 coupled to the input port 22 and through passageways 104, 102 to enter the chamber 90 defined within the bladder 92. In a similar manner, the bladder inlet 98 is coupled to the inlet port 106 on the opposite instrument mounting position 25 through corresponding passageways in similar inner member walls and lateral extensions as shown for the instrument mounting position 24 in FIG. 7.
A spring 112 is mounted within the stationary inner member and the respective end walls of the actuator members, i.e. between the top end wall 60 of the stationary inner member and the bottom dome-shaped cap 72 of the movable outer member. Accordingly, FIG. 3 shows a normal unoperated actuator position wherein the spring 112 moves the outer member 48 to a bottom position, and FIG. 4 shows the valve actuator being operated to move the outer member 48 to the top position thereby compressing spring 112.
In the operation of the actuator 10, fluid under pressure, such as pneumatic pressure supplied by the valve controller instrument 14 to input port 20 is coupled to passageways 104, 102 and through bladder inlet 96 into chamber 90 within the bladder 92 which expands the bladder in a rolling diaphragm action which forces the movable outer member 48 to move upwardly in FIG. 3 so as to carry with it the attached mechanical control element 32 which could be a valve stem or motion conversion linkage if used with a rotary shaft valve. In any event, the driven movement of movable outer member 48 compresses the spring 112 so that the movable outer member has been moved in an upward direction, with respect to the stationary inner member 50 to the position shown in FIG. 4. In a single acting configuration, the input port at instrument mounting position 25 would be closed with suitable plugs. Relieving the pressure within the bladder 90 through the action of the valve controller instrument 14 allows the compressed spring 112 to push the movable outer member 48 downwardly in the configuration shown in FIG. 4.
In accordance with the present invention, the bladder 92 enables a rolling diaphragm action at the bladder perimeter portion 93 instead of an undesired balloon-type action during expansion of the bladder. This can be seen with reference to FIGS. 3 and 4 wherein the bladder perimeter portion 93 contact with the inner member 50--as shown in the deflated bladder condition of FIG. 3, extends from about reference point 60a to reference point 114 along the side wall 62 of the stationary inner member. As the valve actuator is operated by coupling fluid into the bladder chamber 90, the bladder perimeter portion 93 in contact with the side wall 62, merely rolls off of engagement with the side wall 62 of the stationary inner member while simultaneously increasingly engaging the side wall 73 of the movable outer member 48 as shown in FIG. 4.
Thus, in accordance with the present invention, the bladder perimeter portion 93 is expanding in going from FIG. 3 to FIG. 4, with the bladder perimeter portion merely moving from the inside diameter of the bladder to the outside diameter of the bladder in a rolling fashion placing the bladder material under tension. This significantly reduces bladder wear, increases the bladder life and enables repeated actuator operation over extended operating cycles and wide temperature and pressure ranges.
The present invention also provides the ability to utilize the valve actuator 10 in either a fail-closed or a fail-opened condition of the valve--which condition will be decided upon in the event there is a loss of actuator operating pressure. In this aspect of the invention, the power module assembly 28 is reversible after disassembly from the yoke 30 as shown in FIG. 2.
The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art.
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An actuator for fluid control valves with a reversible power module having a stationary inner member and a coaxially aligned movable outer member coupled to the valve flow control element and slidably movable on the inner member. A chamber formed between respective ends of the members includes a preformed bladder. Pneumatic pressure applied to the bladder drives the movable member to actuate the valve in a first direction. A spring returns the movable member in the second direction. The preformed bladder is formed with two pieces including an interconnecting perimeter portion. During bladder actuation the bladder perimeter portion is displaced from the bladder inner diameter to the bladder outer diameter with the bladder material in tension to thereby prolong bladder life.
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BACKGROUND OF THE INVENTION
The most efficient fireplaces are those constructed and arranged to radiate heat back into the room in which the fireplace is located. To accomplish this, it has been proposed to line the fireplace walls with a heat reflecting material such as stainless steel. While this arrangement has been satisfactory for its intended purpose, it is relatively expensive and wasteful since the logs are usually stacked two or three high and two or three deep so that the radiation from the logs in back is blocked by those in the front; thus, the excess logs merely provide the heat required to sustain the fire.
It has been found that to obtain the maximum radiation from each burning log, the logs should be stacked vertically in a single row; that is, one log deep, so that the fresh logs are on top, the burning logs in the middle, and hot coals dropping to the bottom. Grates or log supports designed to accomplish this are heavy, expensive and have failed to provide the proper draft and heat concentration necessary to make the fire reliably self-sustaining.
After considerable research and experimentation, the fireplace grate of the present invention has been devised to provide a simple, lightweight, inexpensive log holder which is easily assembled and provides the maximum radiated heat per pound of wood by supporting the logs and hot embers or coals in a vertical plane to provide a surface area perpendicular to the direction of radiation.
The fireplace grate of the present invention comprises, essentially, a base, an inclined heat radiating back wall detachably connected to the base, and an inclined wire grill, positioned forwardly of the back wall, detachably connected to the base, and adjustable relative to the back wall, whereby the space between the grill and back wall forms a cradle for receiving a single row of vertically stacked logs.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the fireplace grate of the present invention;
FIG. 2 is a side elevational view of the grate showing the wire grill, in phantom, being adjusted forwardly of the back wall; and
FIG. 3 is a view taken along line 3--3 of FIG. 1 showing a single row of vertically stacked logs in the grate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and more particularly to FIGS. 1 and 2 thereof, the fireplace grate of the present invention comprises a base including a plurality of horizontally disposed angle irons 1, 2 and 3 held in parallel, spaced relationship to each other by a transversely extending frame member 4 attached to the respective horizontal legs 1a, 2a, 3a of the angle irons. The vertical legs 1b, 3b of the outboard angle irons 1 and 3 are provided with a plurality of apertures 5 adapted to receive a bolt and wing nut assembly 6 extending through an aligned aperture provided in the lower ends of an inclined mounting plate 7. The inclination of the mounting plates 7 is obtained by cutting the lower end 7a of each plate on a bias and supporting the end of the mounting plate on the horizontal legs 1a and 3a of the angle irons 1 and 3.
The mounting plates 7 are employed for supporting a wire grill 8 in an inclined position relative to the base. While the wire grill may be formed in various configurations, the grill of the present invention comprises a plurality of spaced, reversely bent wire portions 8a interconnected at their lower end portions by a pair of spaced, parallel, transversely extending rods 9 and 10, the ends of the rods 9 and 10 extending through suitable apertures provided in the mounting plates 7.
To complete the basic structure of the grate, an inclined back plate 11 is spaced rearwardly from the wire grill 8, and the lower edge portion thereof is inserted into suitable slots 1c, 2c, 3c provided in the angle irons 1, 2 and 3, whereby the back plate 11 is held in the operative position. The space 12 between the wire grill 8 and back plate 11 forms a cradle for receiving a single row of vertically stacked logs 13, as shown in FIG. 3. A suitable draft of air for supporting the combustion of the logs is provided by the space formed by the floor of the fireplace in which the grate is mounted and the vertical legs 1b, 2b, 3b of the angle irons, and also grooves 11b formed in the back plate 11.
The lowermost log can rest on the top edges of the vertical legs 1b, 2b, 3b of the angle irons 1, 2, 3, or, to increase the draft area, a rectangular grid 14 can be freely mounted in an inclined position within the space 13, as shown in FIG. 3 for supporting the lowermost log. If the grid 14 is not desired, it is merely removed and the lowermost log will rest on the top edges of the vertical legs 1b, 2b, 3b of the angle irons.
To assemble the fireplace grate of the present invention, the lower edge portion of the back plate 11 is inserted into the slots 1c, 2c, 3c formed in the vertical legs of the angle irons 1, 2 and 3, respectively. The wire grill 8 and associated mounting plates 7 are secured to the vertical legs 1b and 3b of the angle irons 1 and 3 by the wing nut assemblies 6 extending through a selected aperture 5 in the vertical legs 1b and 3b, the particular aperture being selected depending upon the diameter of the logs to be burned. Thus, for relatively large diameter logs, the grill 8 would be positioned as shown in phantom in FIG. 2 to provide a wide space 12 between the grill 8 and back plate 11. To accommodate smaller logs, the grill 8 would be mounted as shown in solid lines in FIG. 2, to thereby provide a smaller space 12 for receiving the logs. If the grid 14 is to be used, it is placed in an inclined position in the space 12 with one side of the grid resting on the top edges of the vertical legs 1b, 2b, 3b of the angle irons and abutting the edges of the support plates 7, while the other side of the grid 8 abuts the back plate 11, to thereby provide an inclined surface for supporting the lowermost log as shown in FIG. 3.
In use, the grate is placed in a fireplace with the base supported on the fireplace floor with the back plate 11 resting against the fireplace back wall. The logs 13 are placed in the space 12 between the grill 8 and back plate 11, the logs being stacked vertically in a criss-cross fashion to form a single row, that is, one log deep, whereby the fresh logs will be on top, the burning logs will be in the middle, and the hot embers or coals will drop to the bottom. This arrangement of the logs minimizes the depth of the fire and maximizes the radiation from each burning log, the radiation being enhanced by the hot back plate 11 concentrating the heat into the burning area. A draft for the fire is provided by either the angle irons 1, 2 and 3 or the grid 14 supporting the lowermost log above the fireplace floor, and the inclined back plate 11 deflecting the draft upwardly through the burning logs. By supporting the logs above the fireplace floor, removal of the accumulated ashes from the bottom is also facilitated.
If the grate is not to be used for an extended period of time, it can be easily dismantled for storage by lifting the back plate 11 out of the angle iron slots 1c, 2c, 3c, and removing the wing nut assemblies 6 to disconnect the wire grill 8 from the angle irons 1 and 2.
From the above description, it will be readily understood that the fireplace grate of the present invention provides a simple, lightweight, inexpensive log holder which is easily assembled and insures a reliable, self-sustaining fire which is easily started and maintained, while providing efficient radiation from a minimum of wood burned.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
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A fireplace grate having a base, an inclined heat radiating back wall detachably connected to the base, and an inclined wire grill, positioned forwardly of the back wall, detachably connected to the base and adjustable relative to the back wall; the space between the grill and back wall forming a cradle for receiving a single row of vertically stacked logs.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to an abnormal condition warning apparatus for a sewing machine wherein a warning is generated in voice.
(2) Description of the Prior Art
In conventional sewing machines, detectors such as a thread breakage detector, a thread consumption detector and a drive motor locking detector are installed, and occurrence of abnormal condition in the machine working is indicated by lighting of a warning lamp. This manner has disadvantages, however, in that a worker cannot recognize abnormal portions easily and rapidly by only seeing the lamp blinking to indicate occurence of abnormal condition.
SUMMARY OF THE INVENTION
In view of the above mentioned prior art, an object of this invention is to provide an abnormal condition warning apparatus for a sewing machine, wherein plural detectors are disposed at specific portions of the sewing machine, and in response to the detection the abnormal portion is clearly indicated in voice to a worker.
In order to attain this object, the present invention constitutes an abnormal condition warning apparatus for a sewing machine having stitch forming instrumentalities, comprising: plural detecting means disposed in the sewing machine for detecting the occurence of abnormal conditions in which the stitch forming instrumentalities are prevented from forming a desired stitch pattern, each of the plural detecting means generating a detection signal according to the detection, memory means for permanently storing plural groups of speech data, each of said groups being predetermined to represent one of the abnormal conditions in voice; means for selecting one group from the plural groups according to the detection signal; means for generating an electric signal based on the selected group; and electroacoustic means disposed in the machine for speaking one of the abnormal conditions in response to the electric signal.
Other features and objects of this invention will be made clear in the following description with reference to the accompanying drawings. However, the drawings are for description and not for restriction of the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sewing machine includng a preferred embodiment of the present invention; and
FIG. 2 is a block diagram showing arrangement of circuits of the sewing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will now be described referring to the accompanying drawings. At first, constitution of a sewing machine will be explained. A sewing machine comprises a bracket arm 2, and a pattern display panel 3 disposed on the front surface of the bracket arm 2. On the pattern display panel 3 is displayed a pattern symbol 28 showing each of plural patterns and light emitting diode 27 arranged corresponding to respective patterns. Two pattern selecting switches 23 and a manual switch 26 are also installed. Referring to a block diagram in FIG. 2, a microprocessor 13 reads out stitch data for forming stitch pattern in response to the signals applied thereto and generates command signals for controlling a drive motor 19. The microprocessor 13 acts also as a data selecting circuit 25 in an abnormal condition warning apparatus using speech data as hereinafter described. A pattern selection device 14 including the pattern display panel 3 provides a pattern code signal to the microprocessor 13, said pattern code signal corresponding to a desired pattern selected by the pattern selecting switches 23. A read-only memory (hereinafter referred to as ROM) 15 stores plural groups of speech data representing respective abnormal conditions previously specified corresponding to types of abnormal conditions of the sewing machine, for example, plural voice signals in digital form, and stitch data in digital form for constituting plural stitch patterns previously specified. The ROM 15 generates stitch data in response to the pattern code signal from the microprocessor 13 and provides the data to the microprocessor 13. Such a device as disclosed in U.S. Patent 3,872,808 may be used in the pattern selection device 14. Voice signals in digital form are stored in the ROM 15 as speech data of plural groups. A stitch formation controlling circuit 16 receives stitch data transferred from the microprocessor 13 and provides signals to an actuator 17 for driving a feed dog 30 and a needle 4 in order to form each stitch in the selected pattern in response to the stitch data. A linear actuator is used generally in the actuator 17. A motor driving circuit 18 receives command signals regarding start, stop and speed from the microprocessor 13 and controls a drive motor 19 in response to the signals. The sewing machine as above described is similar to known automatic multi-pattern sewing machines in its construction.
Now, detectors in five systems for detecting abnormal conditions in a sewing machine and an abnormal condition warning apparatus for generating voice signals in response to the detection will be described.
A thread breakage detector 8 disposed in thread feed passage detects the thread tension using a microswitch or the like or optically detects existence of the thread and provides a detection signal to the microprocessor 13 in the thread breakage state. Such a detector as disclosed in U.S. Pat. No. 3,587,497 may be used in the thread breakage detector 8. A presser foot detector 9 detects the type of a presser foot 5 in order to determine whether the pressor foot 5 exchangeably mounted to the lower end of a presser bar 6 is suitable to form the selected stitch pattern or not. The pressor foot detector 9 detects a bar code attached to various types of the presser feet 5 using optical transmission fibers and a light receiver installed to the lower end of the presser bar 6, and provides a detection signal to the microprocessor 13. The type of the presser foot 5 can be detected also by magnetic detecting means. A thread consumption detector 10 detects the amount of thread remaining in a thread bobbin optically and provides a detection signal when the amount of thread becomes less than a prescribed value. Such a detector as disclosed in U.S. Patent 4,178,866 may be used in the thread consumption detector 10. A throat plate detector 11 disposed to mounting portion of a throat plate 7 supplies the microprocessor 13 with a detection signal to distinguish whether the throat plate 7 installed to a prescribed position is for a straight stitch or a zig-zag stitch. Such a device as disclosed in U.S. Pat. No. 3,926,133 may be used for the throat plate detector 11. A timing pulse generator 12 provides pulse signals in response to reciprocation of the needle 4. Interruption or stop of the pulse signal causes the microprocessor 13 to detect that the drive motor 19 has locked due to applying some overload to driving system of the sewing machine including the motor. The pulse signal transmitted from the timing pulse generator 12 to the microprocessor 13 determines the timing to drive the actuator 17 during formation of the pattern.
The ROM 15 stores plural groups of voice signals in the form of digital code and in a predetermined sequence to speak words or sentences, such as "thread broken", which are related to the abnormal conditions to be detected by the detectors in five systems. The voice signals may be prepared in a manner that voice wave form of word according to human pronunciation is quantized in a certain sampling frequency. The voice signal in the ROM 15 is selectively read out in response to a command of the microprocessor 13. Accordingly, the microprocessor 13 together with the ROM 15 constitutes a data generating circuit 24. The voice signal read out by the microprocessor 13 is transmitted to a D/A converter 20 where the signal is converted into analog signal. The converted analog signal is transmitted through a low-pass filter 21 and an amplifier 22 to a speaker 1 disposed on the front surface of a bracket arm 2, thus voice is generated.
The data selecting and generating circuits may be constituted in a manner that human voices for warning are recorded in an endless tape and one selected voice in response to a selection command is regenerated by a regenerating device.
Operation of an abnormal condition warning apparatus for a sewing machine will be described. Prior to sewing operation, one stitch pattern is designated by the pattern selecting switches 23 and code signal of the designated pattern is transmitted from the pattern selection device 14 to the microprocessor 13. The detection signal of the presser foot detector 9 indicating the type of the installed presser foot 5 and the detection signal of the throat plate detector 11 indicating the type of the throat plate 7 are also entered to the microprocessor 13. The microprocessor 13 decides whether the installed throat plate and presser foot conform to the designated stitch pattern. If they do not conform, speech data in digital form, for example, data representing "presser foot caution" or "throat plate caution" is read out from the ROM 15. The read-out digital signal is transferred to the D/A converter 20 and converted into analog signal. High frequency component is eliminated from the analog signal in the low-pass filter 21 and the signal is amplified in the low frequency amplifier. Thus the warning in voice, such as "pressor foot caution" or "throat plate caution" is generated from the speaker 1. When such an abnormal condition is detected, the microprocessor 13 provides a command signal to the motor driving circuit 18 so as to stop the running of the drive motor 19.
When the presser foot and the throat plate conform to the designated pattern, speech data is not read out from the ROM 15, but the sewing machine starts if a manual switch 26 turns on. Stitch data regarding the designated stitch pattern is transmitted from the microprocessor 13 to the stitch formation controlling circuit 16, and the actuator 17 acts to control the work feed and the needle lateral jogging, thus stitching is performed in the designated pattern.
If thread is broken during the machine running, the detection signal representing the thread breakage is transmitted from the thread breakage detector 8 to the microprocessor 13. The microprocessor 13 receives this signal and reads out speech data representing "thread breakage" from specified addresses of the ROM 15 and transfers the speech data to the D/A converter 20. The speech data in digital code is converted by the D/A converter 20 into analog signal, thus the warning "thread breakage" is generated in voice from the speaker 1 in similar manner to above described. At the same time, the microprocessor 13 provides the stop command signal to the motor driving circuit 18 and the drive motor 19 is stopped at once.
When thread in the bobbin is consumed and becomes less than a prescribed amount during the machine running, the detection signal representing the thread consumption is transmitted from the thread consumption detector 10 to the microprocessor 13. Speech data representing "thread consumption" is read out from the ROM 15 in similar manner to above described, and transferred to the D/A converter 20, thus the warning "thread consumption" is generated in voice from the speaker 1.
When overload is applied to driving system such as the needle 4 and the drive motor 19 is locked, generation of pulse signals from the timing pulse generator 12 is stopped. The microprocesser 13 therefore reads out speech data representing "motor abnormal" from the ROM 15, and the speech data is transferred to the D/A converter 20 in similar manner to above described. Thus the warning "motor abnormal" is generated in voice from the speaker 1, and at the same time the motor driving circuit 18 is controlled to stop the drive motor 19.
According to the warnings representing abnormal conditions specifically in voice, a worker can know any abnormal state properly and take a remedy therefor.
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An abnormal condition warning apparatus for a sewing machine is disclosed. Plural detecting means disposed in the sewing machine detect the occurence of abnormal conditions in which stitch forming instrumentalities are prevented from forming a desired stitch pattern, and each of the plural detecting means generates a detection signal according to the detection. Plural groups of speech data are permanently stored in memory means, and each of the groups is predetermined to represent one of the abnormal conditions in voice. Selecting means selects one group from the plural groups according to the detection signal, an electric signal is generated based on the selected group, and electroacoustic means disposed in the machine speaks one of the abnormal conditions in response to the electric signal.
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FIELD OF THE ART
[0001] The present invention is comprised in the technical field of renewable energies, more specifically in the field relating to both solar thermal and thermoelectric energy as well as photovoltaic solar energy.
STATE OF THE ART
[0002] The most widely available thermal solar panels on the market today are two-dimensional planar structures in which solar radiation is concentrated in the fluid carrying pipes by means of metal fins covered with radiation absorbing paint. Heat dissipation is prevented by means of insulation with rock wool or similar elements, but there are still convection losses that cannot be prevented in this concept. The entire system is comprised within an aluminum frame, and the front surface is sheet glass. The entire assembly is heavy, weighing over 30 kg for a 2 m 2 panel.
[0003] These panels, called planar collectors, are relatively inexpensive and highly efficient for warm climates and moderate increases in heat-carrying fluid temperature, up to 50° C., which limits their application both to regions with said climate and to low fluid heating ranges. If the panel is to be placed in cooler areas or if the fluid is to be heated to higher temperatures (over 100° C. and up to 150° C.), two other concepts are needed. On one hand, the so-called vacuum tube collectors are needed. In said collectors, the pipe to be heated is introduced in a glass tube where the vacuum is formed, minimizing heat losses due to convection. On the other hand, the so-called compound parabolic collectors, or CPC, are needed, and they concentrate light on the pipes by means of pseudoparabolic mirrors. In addition to being heavy, both concepts have the major drawback of their price, because they require complicated technology and/or materials increasing the price to two or even three times that of the planar collector.
[0004] Therefore, it is suitable to develop a product in this field which is highly efficient in different regions and temperature ranges, from 50 to 150° C., while at the same time is much lighter and has a price that is comparable to or less than the price for a planar collector.
[0005] As regards photovoltaic solar modules, the most widely available photovoltaic solar modules on the market are planar modules with a glass front, an aluminum frame and virtually the entire surface covered with photovoltaic solar cells. This structure is also heavy, weighing about 20 kg for a conventional 250 W module. Given that solar cells represent by far the most significant part of the cost, there has been a decades-long effort to reduce their surface by replacing them with concentrator elements which are theoretically less expensive and can direct all the light received on them. However, photovoltaic solar concentration systems of many different kinds have failed to successfully penetrate the market up until now. The main reasons are the price as well as the highly complicated final structure of the complete system which requires solar tracking. Furthermore, the concentrations achieved, greater than 20 times the sun, or 20×, and up to 1,000× in high concentration systems usually add another problem: the solar cell heats up excessively, and an active or passive cooling system must be considered. This adds complexity and cost to these systems.
[0006] Holography as an optical technology has many advantages with respect to other optical concentrator systems (lenses or mirrors, for example): it is much more versatile and less expensive than optical concentrator systems. It also eliminates the need for solar tracking when used at a low concentration, whereby reducing system complexity.
[0007] There have been earlier attempts to use holography in solar panels. U.S. Pat. No. 4,863,224, granted to Afian et al., for example, uses a hologram and a prism or plate. However, this solar concentrator must be aligned with the sun and it does not have any passive tracking capacity. Another invention which also has this drawback is U.S. Pat. No. 5,268,985 granted to Ando et al. Said invention comprises a hologram and a total reflection surface, but in addition to requiring tracking, it is constructed for capturing monochromatic light and wastes most of the solar spectrum. U.S. Pat. No. 5,877,874 and U.S. Pat. No. 6,274,860, granted to Rosenberg, discloses a holographic planar concentrator in which at least one multiplexed holographic film, achieving high spectral and angular bandwidths, concentrates the light on solar cells placed in the same plane. This invention has the drawback of having excessive spectral losses and the need for using bifacial cells, as well as the need for placing the entire photovoltaic solar system in a planar location with the ground painted white to reflect the albedo. Patent US20080257400, granted to Mignon and Han, also discloses a holographic planar concentrator but with two different surfaces, in which there are multiplexed transmission and reflection holograms, with the solar cells perpendicular to said collector surfaces. In addition to the losses due to various reflections and transmissions in the various holograms, the main drawback of this design is the difficulty in building it, which can prevent manufacturing it at competitive costs. Finally, patent US20120125403, granted to Orlandi, proposes applying holographic films directly on conventional photovoltaic modules, such that any radiation striking from different angles is used as radiation perpendicular to the plane of the module. Although this concept is highly marketable due to scarce interference in the original design, it does not reduce the weight or the manufacturing cost of current modules.
[0008] None of the aforementioned inventions aims to reduce panel weight, an important factor for both the cost and mounting difficulty (which also has a bearing on the cost of solar energy as an overall concept). The present invention uses plastic materials that are widely available on the market for constructing the panels. Furthermore, it combines not only one or two, but up to three optical elements for concentration purposes, which significantly increases solar spectrum collection, and it does all this at an industrial production cost which is even less than current conventional panels.
DESCRIPTION OF THE INVENTION
[0009] The study of the state of the art shows that the main problem involved in implementing the holography in both thermal and photovoltaic solar applications is collecting as much of the solar spectrum as possible. This refers both to the variation in the angles of incidence throughout the different seasons of the year and the wide range of energetically significant wavelengths which must be collected.
[0010] In terms of wavelengths, in order to collect a significant part of the solar spectrum, the hologram must be capable of collecting at least the region between 500 nanometers (nm) and 1,100 nm. This portion contains 70% of all the energy of the solar spectrum. Yet even more ideally, the hologram must be capable of collecting between 400 nm and 1,200 nm, i.e., 80% of the total spectrum. However, current holograms, particularly reflection holograms, are capable of collecting for each diffraction grating a maximum of 300 nm, and this is by means of special processes. Therefore, at least two superposed, i.e., multiplexed, diffraction gratings will be necessary for capturing the required minimum of 70%.
[0011] However, those wavelengths must be collected throughout the year, from morning to night. Generally, the annual variation of the angles of incidence of sunlight is kept at about 60° in a wide range of terrestrial latitudes. As seen in FIG. 1 , a surface ( 1 ) tilted at latitude will receive radiation ( 2 ) from a smaller angle in winter and radiation ( 3 ) from a larger angle in summer. Radiation ( 4 ) in spring and fall will be received with an angle very close to the perpendicular. The angular variation between (2) and (3) are about 60° as mentioned. Reflection holograms are capable of capturing a maximum variation of ±15°, so in this case at least two multiplexed diffraction gratings are also necessary. Along with the wavelength requirements, at least four multiplexed gratings are needed. Given that the holographic materials lose efficiency as the number of multiplexed gratings increases, this minimum of four gratings is also the maximum imposed by the physics of the material. In other words, the hologram must not capture less, but it cannot capture more than that mentioned previously either if efficiency loss is to be prevented.
[0012] On the other hand, in a planar configuration such as that of FIG. 1 , there is the additional problem that if the quantity of radiation receivers (depicted in FIG. 1 as a pipe ( 6 ) in a thermal solar panel) is to be greatly reduced, then the radiation angle of departure ( 5 ) must be very steep. This presents a problem in hologram construction: such steep angles cannot be obtained in a commercially viable manner without excessive optical losses in the hologram, particularly due to Fresnel reflection. Such reflection occurs in any optical surface, and the larger the angle of incidence with respect to the normal, the greater such reflection.
[0013] It is obvious that a planar solar panel configuration, particularly a planar capture by the hologram, as presented in most of the solutions mentioned in the state of the art, is insufficient and will always lead to limited performances.
[0014] For this reason, the present invention proposes as a solution a three-dimensional structure repeated several times, the 3D unitary structure of which can be observed in a front section view in FIG. 2 for the case of a thermal solar panel. In said figure, the radiation receiver ( 6 ) is a pipe, for example a copper pipe, located in the center of a pseudoparabolic structure formed by several planes or curves ( 7 ) each having a different tilt with respect to one another. FIG. 3 , which is equivalent to FIG. 2 , depicts the photovoltaic solar module where the radiation receiver ( 8 ) is in this case a photovoltaic solar cell housed at the bottom of the 3D unitary structure.
[0015] A system in which the radiation receivers ( 6 ) or ( 8 ) can be substantially reduced is thus obtained. In other words, the distance between pipes in a thermal solar panel and the distance between branches of solar cells in a photovoltaic solar module can be greater. It must be pointed out that the 3D unitary structure is asymmetrical because the angles of incidence of solar radiation ( 2 ) and ( 3 ) are different in winter and summer if the panel is tilted at latitude.
[0016] As seen in FIG. 4 , the only drawback of this configuration is that if the different planes or curves ( 7 ) are projected on the plane tilted at latitude, the variation in the angles of incidence between radiation in winter ( 2 ) and radiation in summer ( 3 ) increases substantially, from the mentioned 60° to more than 150°. It is no longer possible to capture the entire angular variation with two multiplexed diffraction gratings (70% of the spectral bandwidth, however, can still be captured by means of the two wavelength diffraction gratings described above).
[0017] Due to the inability to capture the entire angular variation, the present invention incorporates not only reflection holograms ( 9 ) as a concentrating optical element (see FIG. 5 , always in front section view), but also two more elements. One of them is a highly reflective surface ( 10 ) which can even have an insulating part, such as the insulation foils used in construction. The other element is a transparent optical medium ( 11 ) having high optical quality, such as a silicone or transparent polyurethane, for example. This medium must have a refractive index n close to the refractive index of the holographic material, such that there is no difference due to a change in medium as the radiation goes from one medium to another.
[0018] The 3D unitary structure of the panel is defined as follows (see FIG. 5 ):
a polymeric or plastic base ( 12 ) containing therein the planes or curves ( 7 ) providing the pseudoparabolic shape of the 3D unitary structure of the panel, a highly reflective surface ( 10 ) placed on this polymeric or plastic base ( 12 ), inside the 3D unitary structure of the panel, a reflection hologram with several multiplexed diffraction gratings ( 9 ) which is placed on the highly reflective surface ( 10 ), radiation receivers which are either pipes ( 6 ) or solar cells ( 8 ), and a transparent optical medium ( 11 ) sealing the inside of the 3D unitary structure.
[0024] Therefore, the three optical elements are combined and work in the following manner to capture the entire 150° of variation in the angles of incidence:
a.) The reflection hologram ( 9 ) captures up to about the central 60°. It is constructed such that the beam reflected by diffraction leaves the hologram with an angle greater than the critical angle of the medium ( 11 ) (see below) b.) The highly reflective surface ( 10 ) captures greater angles, about a range of 20° above each side of the central 60°. In other words, with both elements, i.e., the hologram ( 9 ) and the reflective surface ( 10 ), at least one variation in the angle of incidence of 100° can be captured. By reflecting towards the medium ( 11 ) with the same angle of departure, it is assured that within the medium ( 11 ) there is an angle greater than the critical angle (see below), and c.) The medium ( 11 ) has a dual purpose: on one hand, it captures radiation striking with angles greater than the central 100° and reflects them by Fresnel reflection, directing them towards another plane or curve ( 7 ) of the plastic base ( 12 ), where it has already been captured by either the hologram ( 9 ) or the reflective surface ( 10 ). On the other hand, the medium ( 11 ) is constructed with an angle not parallel to and greater than the planes or curves ( 7 ) (see the next paragraph).
[0028] Therefore, it is assured that in the medium ( 11 ) all the radiation returned either as a result of being diffracted from the hologram ( 9 ) or reflected from the reflective surface ( 10 ) does not leave the medium, since it strikes its inner surface with an angle greater than the critical angle. The radiation is therefore returned through total internal reflection (TIR) to within the medium ( 11 ), where either the hologram ( 9 ) or the reflective surface ( 10 ) will work again successively until reaching the radiation receiver ( 6 ) (pipes for a thermal solar panel) or ( 8 ) (photovoltaic solar cells for a photovoltaic solar module). The TIR has 100% efficiency, so there are no losses in it. As regards the hologram ( 9 ) or the highly reflective surface ( 10 ), efficiencies exceed 95% and even 98%, whereby minimizing losses in each diffraction or reflection. Furthermore, the 3D unitary structure is designed so that the maximum number of diffractions and/or reflections until reaching the radiation receiver ( 6 ) or ( 8 ) is not more than three, so losses are even lower.
[0029] To better explain these effects, FIGS. 6 to 8 depict different times of the year with different angles of incidence. In a non-exclusive configuration, there are five planes ( 7 ) referred to as ( 7 a ) to ( 7 e ), each having a different tilt.
[0030] In FIG. 6 , early morning radiation in winter ( 2 ) hits the planes or curves ( 7 a ) and ( 7 b ) with a very steep angle. Fresnel reflection will occur mainly in those planes, sending radiation to the planes or curves ( 7 d ) or ( 7 e ). Upon entering the medium ( 11 ), the radiation refracts with the corresponding angle. Depending on that angle of arrival, the radiation will be captured by either the hologram ( 9 ) or the reflective surface ( 10 ). Upon being diffracted or reflected, respectively, the radiation runs through the medium ( 11 ) with an angle greater than the critical angle, so upon reaching the medium-air interface, total internal reflection (TIR) will occur, sending the radiation again to within the medium, and several diffractions and/or reflections (maximum 3) occur successively, until reaching the radiation receiver ( 6 ) or ( 8 ) (the figure shows the example of a thermal solar panel, the radiation receiver of which is a pipe ( 6 )).
[0031] In FIG. 7 , mid-day radiation in summer ( 3 ) hits the planes or curves ( 7 d ) and ( 7 e ) with a very steep angle. Fresnel reflection will occur mainly in those planes, sending radiation to the planes or curves ( 7 a ) or ( 7 b ). Upon entering the medium ( 11 ), the radiation refracts with the corresponding angle. Depending on the angle of arrival, the radiation will be captured by either the hologram ( 9 ) or the reflective surface ( 10 ). Upon being diffracted or reflected, respectively, the radiation runs through the medium ( 11 ) with an angle greater than the critical angle, so upon reaching the medium-air interface, total internal reflection (TIR) will occur, sending the radiation again to within the medium, and several diffractions and/or reflections (maximum 3) occur successively, until reaching the radiation receiver ( 6 ) or ( 8 ) (the figure shows the example of a thermal solar panel, the radiation receiver of which is a pipe ( 6 )).
[0032] In FIG. 8 , radiation in spring or fall ( 4 ) enters the medium ( 11 ) and refracts with the corresponding angle. Depending on the angle of arrival, the radiation will be captured by either the hologram ( 9 ) or the reflective surface ( 10 ). Upon being diffracted or reflected, respectively, the radiation runs through the medium ( 11 ) with an angle greater than the critical angle, so upon reaching the medium-air interface, total internal reflection (TIR) will occur, sending the radiation again to within the medium, and several diffractions and/or reflections (maximum 3) occur successively, until reaching the radiation receiver ( 6 ) or ( 8 ) (the figure shows the example of a thermal solar panel, the radiation receiver of which is a pipe ( 6 )).
[0033] In this manner, the mentioned 3D unitary structure thus captures radiation during every season of the year and very efficiently directs it to the radiation receiver ( 6 ) or ( 8 ). A thermal solar panel or a photovoltaic solar module having a power that is equivalent to those available on the market today (see FIGS. 9 and 10 , respectively) is obtained by joining several, for example, 8 to 10 of these 3D unitary structures together. The asymmetry of the 3D unitary structure means that both the left and right sides are not at the same height. However, shading losses are reduced in the early morning in winter and do not reach a yearly total of 3%.
[0034] Both the base ( 12 ) made of an environmentally resistant polymeric material resistant and the medium ( 11 ) made of an environmentally resistant optical polymeric material (silicone or polyurethane, for example) can be extruded by means of plastic molding. They assure rigidity, thereby making a frame unnecessary, as well as a significant weight reduction. On the other hand, since the base ( 12 ) is made by extrusion from a mold, it can include in the same extrusion all the anchoring elements necessary for fixing the panels to the mounting structures of any photovoltaic solar system. It can also include, for example, in the case of a thermal solar panel, the openings or cavities necessary for housing at the ends of the panel the collector pipes ( 13 ) having a larger diameter (see FIG. 11 ). In a photovoltaic solar module, it will also include the openings necessary to make all kinds of electric connections between cells.
[0035] It must be mentioned that there is a fundamental difference between a thermal solar panel and a photovoltaic solar module affecting the present design: in a thermal solar panel, it is of interest to retain heat inside the structure to minimize losses and assure heating of the heat-carrying fluid (referring to losses due to conduction, since losses due to convection are insignificant as the pipes are completely imbued in a solid medium). In a photovoltaic solar module, however, as much heat as possible should be dissipated since the efficiency of the solar cells decreases with the temperature thereof.
[0036] In the present design, this difference is resolved by choosing different plastic materials both for the plastic base ( 12 ) and for the medium ( 11 ), which are in any case environmentally resistant. Specifically, for a thermal solar panel, plastic materials with very low thermal conductivity K, for example around 0.02-0.03 W·m −1 ·K −1 , are of interest. For a photovoltaic solar module, the reverse is applicable. Therefore, for photovoltaic solar modules, the plastic materials making up both the plastic base ( 12 ) and the medium ( 11 ) must have thermal conductivity greater than 0.05 W·m −1 ·K −1 , for example, and even greater than 0.07 W·m −1 ·K −1 .
DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 shows the variation in the angles of incident solar radiation between winter ( 2 ) and summer ( 3 ) on a surface ( 1 ) tilted at latitude. Early morning solar radiation in winter ( 2 ) strikes the surface ( 1 ) with a smaller angle, whereas mid-day solar radiation in summer ( 3 ) strikes that same surface ( 1 ) with a larger angle. The difference between both angles is about 60° for many latitudes. Radiation in spring or fall ( 4 ) strikes said surface ( 1 ) in a virtually perpendicular manner. If said radiation is to strike radiation receivers ( 6 ) spaced far enough away from one another so as to make a thermal solar panel or photovoltaic solar module economically viable, then the radiation angle of departure ( 5 ) must be very steep, which is very expensive and complicated in current holographic technology.
[0038] FIG. 2 shows a front section view of the 3D unitary structure of the proposed thermal solar panel. Several planes or curves ( 7 ) each having a different tilt with respect to one another form a pseudoparabolic structure, the center of which is occupied by the radiation receiver, in this case a pipe ( 6 ).
[0039] FIG. 3 shows a front section view of the 3D unitary structure of the proposed photovoltaic solar module. Several planes or curves ( 7 ) each having a different tilt with respect to one another form a pseudoparabolic structure, the bottom of which is occupied by the radiation receiver, in this case photovoltaic solar cells ( 8 ).
[0040] FIG. 4 shows a depiction of the variation in incident radiation angle between winter ( 2 ) and summer ( 3 ), if the different planes or curves ( 7 ) are projected on the plane tilted at latitude. This variation in angles exceeds 150°.
[0041] FIG. 5 shows a front section view of the 3D unitary structure of the solar panel (in this case, a thermal solar panel) with the different elements making up same: a plastic base ( 12 ) the inner surface of which is made up of the planes or curves ( 7 ) each having a different tilt with respect to one another; a highly reflective surface ( 10 ) covering said planes or curves ( 7 ); a reflection hologram ( 9 ) with several multiplexed diffraction gratings covering the reflective surface ( 10 ), and a transparent optical medium ( 11 ) sealing the entire assembly. The radiation receiver, in this case a pipe ( 6 ), is arranged therein.
[0042] FIG. 6 shows the optical path of early morning incident radiation in winter ( 2 ) as it reaches the 3D unitary structure of the solar panel (in this case a thermal solar panel). Said radiation ( 2 ) is reflected in the planes ( 7 a ) and ( 7 b ) by Fresnel reflection directly on the surface of the medium ( 11 ), towards the planes ( 7 d ) or ( 7 e ). Upon reaching the medium ( 11 ) therein, it refracts with the corresponding angle and hits the reflection hologram ( 9 ) or the highly reflective surface ( 10 ). The latter diffract or reflect the radiation, respectively, towards the medium ( 11 ) again with an angle greater than the critical angle, such that TIR occurs within the medium. Successive diffractions and/or reflections lead the radiation towards the radiation receiver (in this case a pipe ( 6 )).
[0043] FIG. 7 shows the optical path of mid-day incident radiation in summer ( 3 ) as it reaches the 3D unitary structure of the solar panel (in this case a thermal solar panel). Said radiation ( 3 ) is reflected in the planes or curves ( 7 d ) and ( 7 e ) by Fresnel reflection directly on the surface of the medium ( 11 ), towards the planes or curves ( 7 a ) or ( 7 b ). Upon reaching the medium ( 11 ) therein, it refracts with the corresponding angle and hits the reflection hologram ( 9 ) or the highly reflective surface ( 10 ). The latter diffract or reflect the radiation, respectively, towards the medium ( 11 ) again with an angle greater than the critical angle, such that TIR occurs within the medium. Successive diffractions and/or reflections lead the radiation towards the radiation receiver (in this case a pipe ( 6 )).
[0044] FIG. 8 shows the optical path of incident radiation in spring or fall ( 4 ) as it reaches the 3D unitary structure of the solar panel (in this case a thermal solar panel). In all the planes or curves ( 7 a ) to ( 7 e ), upon reaching the medium ( 11 ), it refracts with the corresponding angle and hits the reflection hologram ( 9 ) or the highly reflective surface ( 10 ). The latter diffract or reflect the radiation, respectively, towards the medium ( 11 ) again with an angle greater than the critical angle, such that TIR occurs within the medium. Successive diffractions and/or reflections lead the radiation towards the radiation receiver (in this case a pipe ( 6 )).
[0045] FIG. 9 shows a front section view of a complete thermal solar panel made up of several 3D unitary structures (in this case eight). The radiation receiver in a thermal solar panel consists of pipes ( 6 ).
[0046] FIG. 10 shows a front section view of a complete photovoltaic solar module made up of several 3D unitary structures (in this case eight). The radiation receiver in a photovoltaic solar module consists of photovoltaic solar cells ( 8 ).
[0047] FIG. 11 shows a possible non-exclusive embodiment of a thermal solar panel. Eight 3D unitary structures include eight pipes ( 6 ) having an outer diameter of 8 mm, for example, welded to two collector pipes ( 13 ) having a larger diameter, for example, 18 mm.
[0048] FIG. 12 shows a possible non-exclusive embodiment of a photovoltaic solar module. Eight 3D unitary structures include eight branches of photovoltaic cells ( 8 ) of 31×125 mm each, for example. The connection between them is very versatile due to openings in the plastic base ( 12 ) allowing any kind of connection between cells.
EMBODIMENTS OF THE INVENTION
[0049] In a preferred but non-exclusive configuration, both the thermal solar panel and the photovoltaic solar panel will consist of eight 3D unitary structures as described in FIGS. 2 to 10 . The dimensions of said structures will be about 80 mm in height by 120 mm in width and a length of 1.5 meters. Therefore, the solar panel will have dimensions of about 1,500×1,000×80 mm, i.e., very close to the magnitudes of any standard panel. Both the plastic base ( 12 ) and the covering and sealing medium ( 11 ) are made of environmentally resistant plastic materials, and furthermore the base can adapt to any shape, whereby reducing material used, and the total weight can be reduced to more than half the weight of a standard commercial panel.
[0050] Since the plastic base ( 12 ) can be made in a mold, it can include all the necessary elements, including anchors for the mounting system or openings for versatile connection of the photovoltaic solar cells, both in series and in parallel. Likewise, for the case of a thermal solar panel, said plastic base ( 12 ) can be made with the necessary extensions for resistant to the elements taking in the collector pipes ( 13 ) (see FIG. 11 ).
[0051] In the case of a thermal solar panel, the radiation receivers are pipes ( 6 ). In the described embodiment, they can be copper pipes having an outer diameter of 8 mm. The collector pipes ( 13 ) have a larger diameter, for example, 18 mm. Since there is a total number of eight pipes ( 6 ), the fluid heating capacity achieved is similar to that of a conventional planar collector. However, the efficiency thereof will be improved for heating fluids at high temperatures because sealing with the medium ( 11 ) minimizes losses due to convection. Furthermore, construction with materials having low thermal conductivity also significantly reduces losses due to conduction.
[0052] The photovoltaic solar module in this embodiment can consist of an array of 120 cells of 31×125 mm, attached in eight branches of 15 cells each. The complete module will therefore have dimensions of about 1,800×1,000×80 mm. If conventional cells having 17% efficiency are used, this configuration obtains a module having a rated power of about 250 W. To obtain the same electrical parameters as a conventional photovoltaic module of the same power, the connection must be made with four branches in parallel, connected in series with the next four branches.
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The present invention relates to a solar panel with three-dimensional (3D) unitary structures or cavities that is made entirely of plastic materials and applicable to both a thermal solar panel and a photovoltaic solar module. The difference between both cases is that in the first case, the structure incorporates pipes ( 6 ) for a heat-carrying fluid, whereas in the second case it is provided with photovoltaic solar cells ( 8 ). The type of material with which they are constructed also differs: while the entire panel in both cases is still made of plastic or polymeric materials, the thermal solar application uses materials with very low thermal conductivity for retaining heat, whereas the photovoltaic application is carried out with materials with high thermal conductivity precisely for dissipating heat and preventing a decrease in cell efficiency due to heating. The assembly is very lightweight since it is made of plastic materials, and it also prevents the need for aluminum frames or external securing systems since the rigidity is assured by the structure itself, and plastic injection allows directly incorporating any securing or gripping system. It also allows adding any opening for connecting solar cells to one another. On the other hand, each 3D unitary structure concentrates sunlight on the end solar radiation receivers (pipes ( 6 ) or cells ( 8 )), covering the entire seasonal and daily spectrum of angles of incidence, without needing active solar tracking. The thickness of said structure is quite small as a result of taking advantage of the concentrating advantages of not only one but three optical elements: on the plastic base ( 12 ) there are placed a highly reflective surface ( 10 ), a reflection hologram ( 9 ) having a wide spectral and angular bandwidth, and a transparent optical medium ( 11 ) with a refractive index and tilt angle such that it traps the light therein by total internal reflection (TIR). Optical losses are therefore significantly reduced and a large part of the solar spectrum is directed towards the radiation receiver.
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FIELD OF THE INVENTION
The invention relates to a method for producing uniform nonwoven webs from unordered fibre material, and to an apparatus for carrying out such a method.
BACKGROUND OF THE INVENTION
There are numerous methods and appliances for the qualitative and quantitative testing of textile fibres. In many test methods, the unordered fibre material, for example cotton in flock form, cannot be measured immediately, but must first be processed into nonwoven webs having a parallelized fibre position. These webs are then used as test samples for obtaining measured quality values on the fibre material and, in the form of continuous nonwoven webs, as a preliminary step in the manufacture of threads or yarns from the fibre material.
Known appliances for the opening of fibre flocks consist conventionally of a pair of feed rollers and of an opening drum. A subsequent cylinder receives the opened material, and then stores it or transports it further. The pair of feed rollers ensures controlled material guidance which is imperative in view of the high degree of opening necessary in the fibre flocks. In such opening appliances for fibre flocks, there is a need to produce the desired sliver, if possible, without the fibre being damaged. Appliances of this type according to the state of the art, for example cards, have a high throughput, but, at the same time, the fibres are nevertheless damaged to a considerable extent. In cards according to the state of the art, it is also already known to structure the feed rollers, for example by the formation of spirals on the surface of the feed rollers or on a clothing having elements arranged in the direction of run and resembling small hooks. These structures have primarily the function of preventing the fibres from adhering to the rollers. A selective retention of the fibres is not possible with these structures, thus leading to increased fibre damage in the fibre samples obtained thereby.
During the feed Of unordered fibre material by means of a pair of feed rollers to an opening roller provided with a "card clothing", the fibre material is opened and a uniform nonwoven is obtained from it. During this, the pair of feed rollers moves preferably at a lower circumferential speed than the opening roller. At least one feed roller can likewise be provided with a "card clothing", the elements of this "clothing" extending counter to the direction of rotation of the feed roller. The pair of feed rollers retains the still unordered fibre material selectively along a line, while the "card clothing" of the opening roller continuously seizes some of the fibres and opens them. A nonwoven is then obtained from these on the subsequent folding roller.
In textile technology, the "card clothing" of a roller is meant to describe phrase the attachment of a series of narrow bands on the outer surface of the roller, which are equipped with small teeth or small hooks usually inclined either in the direction of rotation or counter to this. Likewise, a corresponding design of the outer surface of the roller itself, which can be obtained, for example, by engraving or rolling and by means of which small teeth or small hooks are attached to the outer surface of the roller, can also be designated as a clothing. For the sake of brevity, such small teeth and small hooks will be combined hereafter under the term "small hooks".
In the method mentioned, the individual fibres of the unordered fibre material are retained only along a line. Now if the opening roller draws on a longer fibre, then the remaining fibres behind the retaining line are drawn towards the feed rollers. There is consequently always an excess of fibre material between the feed rollers, thereby increasingly reducing the selective effect of the clothing on one of the two feed rollers. Finally, the fibre material is clamped again. Now if a fibre is seized by the opening roller, then the retaining force is so high that the fibre is torn off. The resulting nonwoven web therefore no longer fully possesses the quality features of the unordered fibre material and consequently can no longer be considered as a completely representative test sample. However, the torn-off pieces of the long fibres also have a quality-reducing effect on the yarn when the nonwoven web is used as a preliminary stage in yarn production.
Furthermore, EP-B1-0,247,420 discloses an appliance for ordering the ends of fibres for fibre-length measurement, in which a nonwoven is introduced into a needle-type transport device consisting of a plurality of needle combs and is transported intermittently by this to a gripper device, by means of which a sample can be extracted from the nonwoven. The needle-type transport device in this known appliance consists of a "needle bed". This term is meant to describe a series of parallel combs which are equipped with needles and which can be moved transversely relative to the comb direction. While the nonwoven is at rest, the comb of the needle bed which is the foremost in the transport destination direction is moved into the last position of a lower comb series having an opposite direction of transport. The comb located in the foremost position and belonging to this lower comb series is simultaneously moved back into the needle bed as the rearmost comb. During transport, the needle bed has no appreciable influence on the orientation of the fibres in the nonwoven. The needle bed serves merely to retain the nonwoven while a part sample is being obtained in order to determine the fibre-length distribution.
Further needle-type transport systems, already on the market, of N. Schlumberger & Cie. NSC are known, for example under the designation "Intersectingstrecke GN 6" ["Intersecting drafting frame GN 6"] (Company prospectus Intersectingstrecke GN6, pages 8/9, and Company prospectus GN6, page 5) or "Kettenstrecke GC13"["Chain drafing frame GC13"] (Company prospectus, page 5), in which, instead of a gripper (as in EP-B1-0,247,420), a pair of rollers is mounted, and by means of this slivers or nonwovens can be combed, unfelted and folded. However, these known needle-type transport systems or needle-type drafting frames are not suitable for the opening of unordered fibre material.
The object on which the invention is based is to provide a method by which a uniform nonwoven web can be produced from unordered and unopened fibre material better than in the disclosed methods, along with the greatest possible preservation of the fibre quality, especially the fibre-length distribution.
Further advantageous embodiments of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Two exemplary embodiments of the invention, which at the same time explain the operating principle, are illustrated in the drawings and are described in more detail below, in which:
FIG. 1 shows a diagrammatic representation of an apparatus for carrying out the method according to the invention;
FIG. 2 shows a diagrammatic representation of a modified apparatus for carrying out the method according to the invention;
FIG. 3 shows a partial section through a needle-type drafting frame according to the state of the art; and
FIG. 4 shows a partial section, similar to that of FIG. 3, through an apparatus according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus 1 illustrated in FIG. 1 consists of an open supply container 2, in which unordered fibre material 3 is located, a pair of feed rollers 4, 5 with a first feed roller 4 and a second feed roller 5, and a needle bed 6 with an upper comb series 11 and a lower comb series 12. The needle bed 6 consists of individual combs 7,i which are equipped with needles that engage into a still unopened nonwoven web 10 to be manufactured by the apparatus and which move from the pair of feed rollers 4,5 in the direction of the opening roller 8 by means of a transport device (not shown). Further details of the needle bed 6, especially relating to its transport device, are described in EP-B1-0,247,420 and, moreover, are known from the abovementioned appliances on the market, for example of N. Schlumberger & Cie.
The opening roller 8 is followed by a cylinder 9, preferably in the form of a folding roller, on which the opened fibres are folded, thus finally resulting in the opened nonwoven web 10.
Since the circumferential speed of the opening roller 8 is much higher than the transport speed of the needle bed 6, the fibres seized by the opening roller 8 are immediately drawn out of the nonwoven and are transported as individual fibres onto the cylinder 9, with the result that a uniform opened nonwoven web 10 is obtained. The fibre tufts of differing density are thus opened by means of this drawing-out operation.
The unordered and unopened fibre material 3 located in the supply container 2 is continuously seized and discharged by the pair of feed rollers 4,5 in quantities which are small in comparison with this supply. At the same time, the nonwoven web 10 is preformed between the feed rollers 4,5, runs by means of the combs 7,i of the needle bed 6 to the opening roller 8 and further to the cylinder 9 (preferably in the form of a folding roller), with the conversion of the unordered fibre material 3 into a nonwoven web 10 consisting of opened fibres being perfected with each transfer.
The needle bed 6 runs slightly faster than the circumferential speed of the feed rollers 4,5, so that no lap can occur between the feed rollers 4,5. The pair of feed rollers 4,5 discharges the quantities of fibre material 3 to be drawn off onto the needle bed 6 which consists of combs 7,i movable individually in the direction of the nonwoven web 10 and equipped with needles. The needles of the combs 7,i take up the fibre material 3. As a result of this operation, the fibre material 3 is converted into a nonwoven web 10. In the textile industry, the term "opening" is meant to describe the increase in the state of order of a fibre structure, highly entangled fibres being drawn apart from one another or "separated". This opening takes place during the transfer of the nonwoven web 10 onto the opening roller 8.
The transport device (not shown) of the needle bed 6 additionally causes the following movements: the particular comb 7,n closest to the feed rollers 4,5 in the upper comb series 11 is transferred, in the course of the transport movement, into the comb position 7,l closest to the feed rollers 4,5 in the needle bed 6. At the same time, the comb 7,n/2 closest to the opening roller 8 in the needle bed 6 is transferred into the comb position 7,n/2+1 closest to the opening roller 8 in the upper comb series 11. Thus, the combs 7,i are continuously exchanged cyclically and are moved along the needle bed 6 by means of the transport device. The movement of the transport device can take place continuously or intermittently. The needle bed 6 must expediently be longer than the largest fibre length which occurs.
Located on the side of the needle bed 6 on which the nonwoven web 10 runs is a pressing-in device 12 which moves towards the needle bed 6 and back again, at the same time passing through between the combs 7,i and repeatedly pushing the nonwoven web 10 back into the needle bed 6. As a result, in contrast to the "needle-type drafting frames" according to the state of the art, the work can be carried out with a one-sided needle bed.
As shown in FIG. 2, the needle bed 6 can also take the form of a pair of needle bands 16. The two needle bands 16 equipped with needles 17 run on two respective pairs of drive cylinders 22. The drive cylinders 22 can be driven electromotively (not shown in the drawing) and can be controlled together with the remaining elements of the apparatus 1. The two needle bands 16 are arranged parallel to one another in such a way that their needles 17 can engage in one another and thereby take up the fibre material 3. For this purpose, the respective pairs of drive cylinders 22 of the two needle bands 16 are to be moved in opposition, so that the parts of the two needle bands 16 bearing on one another move towards the opening roller 8 in the same direction.
The remaining elements of this modified apparatus are already described in connection with FIG. 1. The advantage of this modified version is a mechanism which involves little outlay and which is therefore cheaper.
In the two embodiments according to FIG. 1 or 2, a limiter 13 is expediently installed between the opening roller 8 and the needle-type transport device 6;16 and prevents the fibres from being lifted vertically out of the needles 7;17 by the opening roller 8, thus resulting in a reduction in the retaining force and impaired opening.
A holding-down device 14 is expediently mounted on a lever 15 between the opening roller 8 and the cylinder 9 (preferably in the form of a folding roller). In the case of a multi-layer application of the nonwoven web on the cylinder 9, this holding-down device 14 ensures that the fibre fractions or fractions of nonwoven web previously applied to the latter are held down, for example before a new fraction of nonwoven web is added.
At least one of the feed rollers 4,5 can possess knobs, that is to say nipple-like elevations on its outer surfaces, or a clothing having small hooks counter to their running direction, in order to bring about a better fibre draw-in.
The opening roller 8 is expediently equipped with a clothing, the small hooks of which lie in the direction of run of the opening roller 8. The cylinder 9, preferably taking the form of a folding roller, should also be equipped with a clothing having small hooks in the direction of run, so that the opened fibres on the opening roller 8 can be received. The circumferential speed of the cylinder 9 must be higher than that of the opening roller 8.
The variations in fibre-length distribution are minimal in the method according to the invention. The opening according to the invention of the fibres takes place between the needle-type transport device 6;16 and the opening roller 8. The needle-type transport device 6;16 generates the retaining force and the opening roller 8 the drawing-out force. These two forces must be coordinated with one another in the best possible way; if the two forces are too high, the fibre is torn apart; if the two forces are too low, the opening which can be achieved is poor. The advantage of the method according to the invention is that the retaining force is selective and over a large area. Selective means, in this respect, that each fibre is retained individually according to its length by a few needles. In the conventional clamping method according to the state of the art, the fibres are clamped along a line, thus resulting in an excessively high retaining force and therefore in fibre damage. As regards retention along a line, the fibres are increasingly compacted behind the retaining line, thus leading to an increase in the retaining force and to damage to the fibres.
FIGS. 3 and 4 illustrate the problem of small hooks of fibre. As shown in FIG. 3, in the methods according to the state of the art, the situation can arise that the needle tip 21 of the needle comb 7 is surrounded by a fibre 20 forming a closed loop. If, as in the state of the art, the drawing-off device consists of a pair of rollers 18,19 which clamps the fibres along a line and which thus draws them out of the fibre material, then the fibre 20 is necessarily destroyed.
As shown in FIG. 4, in the method according to the invention this problem is solved by the use of an opening roller 8 having clothings. The fibre 20 forming a small hook is received by the opening roller 8 only when the retaining needle is removed. The drawing-off forces are therefore likewise selective, in contrast to the clamping line in the "needle-type drafting frame" according to the state .of the art (FIG. 3). In the method according to the invention, therefore, the fibre-length distribution is better preserved than in the methods disclosed hitherto.
The method according to the invention thus achieves the object of producing a uniform nonwoven web 10 from unordered fibre material 3 better than the disclosed methods, along with the greatest possible preservation of the fibre quality, especially the fibre-length distribution.
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A method for producing uniform nonwoven webs from a supply of unordered fibre material includes discharging a quantity of fibre material onto a needle-type transport system having needles which are movable along a transport path, taking-up the fibre material by way of the needles on the needle-type transport system, transporting the fibre material in the needle-type transport system to an end of the transport system, discharging the fibre material onto an opening roller, separating the discharged fibre material on the opening roller and transferring the fibre material which has been separated on the opening roller onto a cylinder. An apparatus for producing uniform nonwoven webs includes a needle-type transport system for transporting fibre material along a transport path, an opening roller positioned along the transport path adjacent one end of the transport system and a rotatable cylinder positioned adjacent the opening roller for receiving the fibre material from the opening roller.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 12/955,053, filed Nov. 29, 2010, which is a continuation application of U.S. patent application Ser. No. 12/652,408, filed Jan. 5, 2010 (now U.S. Pat. No. 7,865,768), which is a continuation of U.S. patent application Ser. No. 11/904,061, filed Sep. 25, 2007 (now U.S. Pat. No. 7,661,019), which is a continuation of U.S. patent application Ser. No. 11/471,118, filed on Jun. 19, 2006 (now U.S. Pat. No. 7,290,167), which is a continuation of U.S. patent application Ser. No. 11/228,859, filed on Sep. 16, 2005 (now U.S. Pat. No. 7,191,358), which is a continuation of U.S. patent application Ser. No. 10/387,188, filed on Mar. 11, 2003 (abandoned), the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention is generally related to the field of clustering systems and remote mirroring technology.
[0003] The use of clustering systems to accomplish fault-tolerance and/or load-balancing is becoming increasingly popular. Generally speaking, a clustering system may provide redundant resources so that if one portion of the system experiences failure, another portion can take over affected tasks or otherwise provide recovery from the failure. Also, a clustering system may use its redundant resources to process tasks in a more distributed manner, allowing different portions of the system to work inparallel in accomplishing tasks.
[0004] A typical clustering system may be made up of two or more nodes, each having its own processing and storage capabilities. In one particular use of a clustering system, a primary node may comprise of a server and associated storage devices, while a secondary node may also comprise of another server and associated storage devices. The secondary node may be created to be similar to the primary node, in terms of processing, storage, and other capabilities. Here, the clustering system may maintain exact correspondence between the data storage of the primary node and the data storage of the secondary node, such that any write or read to data storage at the primary node is replicated at the secondary node. If the primary node fails as it performs its various tasks, the secondary node may take over the tasks performed by the primary node. For example, if a web server that is configured as a primary node in a clustering system fails for some reason, a secondary node may take over and serve web server functions in place of the failed primary node. A web site supported by such a system thus continues to operate with little or no down time. Web site visitors may continue to visit the associated web site as if no failure had occurred. In this example, providing a primary and a secondary node of similar capabilities allows the secondary node to be capable of taking over the tasks previously performed by the primary node.
[0005] In other situations, the secondary node may have lesser capabilities than the primary node. For example, if the secondary node is only designed to temporarily take over the tasks of the primary node, or if the secondary node is only designed to record periodic snap shots of the data storage of the primary node, it may be sufficient to create the secondary node with lesser capabilities. This may be especially true if the cost associated with creating a similarly capable secondary node is to be avoided, or if failure of the primary node is not expected to extend beyond a certain amount of time. Thus, depending on the situation, the required capabilities of the secondary node may vary.
[0006] The correspondence between the data storage of a primary node and the data storage of a secondary node storage may also be referred to as remote mirroring. This is especially the case if the data storage of the primary node is at a geographically distant location from the data storage of the secondary node. Remote mirroring may be carried out by different portions of a system. For example, in host-based remote mirroring, a host, such as a server, may be principally responsible for maintaining the correspondence between the data storage of the primary node and the data storage of the secondary node. In storage-based remote mirroring, a storage system, such as a storage area network (SAN), may be principally responsible for maintaining such correspondence. Depending on the implementation, remote mirroring may require separate software and equipment installation and/or configuration, in addition to that required by other parts of the clustering system.
[0007] Currently, in order to realize the many advantages of a clustering system, the multiple nodes of a clustering system must be established by a system administrator. For example, in a clustering system having a primary and a secondary node, the system administrator must decide exactly what should be the processing, storage, and other capabilities of the secondary node, install or identify available resources meeting those capabilities, install required software, and perform necessary configurations to set up the clustering system. These steps involve factors that can be overwhelmingly complex and difficult to analyze for the system administrator, even if that person is an expert. Thus, the administrator may only be able to make a rough guess, in an ad hoc manner, as to what storage capability is needed for the secondary node. As discussed above, the required storage capability of the secondary node may vary from situation to situation, and it may not always be ideal to simply mimic the storage capability of the primary node.
[0008] Furthermore, after the desired processing, storage, and other capabilities of the secondary node is decided, the administrator must go about looking for existing equipment in the system that fit the description, or install such equipment. In a large system having many different components, it may be extremely difficult and time-consuming for an administrator to search through all available resources in order to find the appropriate equipment. Finally, after the appropriate resources are decided and located, software installation and configuration may take additional time and effort. Thus, while clustering systems provide import fault-tolerance and/or load-balancing capabilities, the deployment of clustering systems remains largely a difficult and imprecise undertaking.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a method, apparatus, article of manufacture, and system for establishing redundant computer resources. According to one embodiment, in a system including a plurality of processor, a plurality of storage devices, and a management server connected via a network, the method comprises storing device information relating to the processor devices and the storage devices and topology information relating to topology of the network, identifying at least one primary computer resource, the at least one primary computer resource including at least one primary processor device and at least one portion of storage implemented in at least one primary storage device, selecting at least one secondary computer resource suitable to serve as a redundant resource corresponding to the at least one primary computer resource based on the device information and the topology information, the at least one secondary computer resource including at least one secondary processor device and at least one portion of storage implemented in at least one secondary storage device, and assigning the at least one secondary computer resource as a redundant resource corresponding to the at least one primary computer resource.
[0010] If the at least one primary storage device has storage-based remote mirroring function, the at least one secondary computer resource may be selected such that the at least one secondary storage device also has storage-based remote minoring function and is accessible from the at least one primary storage device.
[0011] In one embodiment, the at least one secondary computer resource is selected based on at least one user-specified policy, which may include performance of the at least one secondary computer resource, reliability of the at least one secondary computer resource, and/or cost of the at least one secondary computer resource.
[0012] In another embodiment, the step for selecting the at least one secondary computer resource comprises the steps of selecting at least one candidate suitable to serve as a redundant resource corresponding to the at least one primary computer resource, presenting the at least one candidate to a user, and receiving input from the user indicating selection, from the at least one candidate, of the at least one secondary computer resource.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram of a clustering system in accordance with at least one embodiment of the present invention.
[0014] FIG. 2 is an illustration of a mapping table.
[0015] FIG. 3 is an illustration of a logical unit number (LUN) binding table.
[0016] FIG. 4A is an illustration of a discovery list.
[0017] FIG. 4B is an illustration of a functional discovery list that may be maintained in addition to or in place of the discovery list shown in FIG. 4A .
[0018] FIG. 5 is an illustration of a topology table.
[0019] FIG. 6A illustrates a fibre channel switch (FC-SW) zoning configuration table.
[0020] FIG. 6B illustrates a different FC-SW zoning configuration table.
[0021] FIG. 6C illustrates a storage-based replication configuration table.
[0022] FIG. 6D illustrates a host-based replication configuration table.
[0023] FIG. 6E illustrates a cluster configuration table.
[0024] FIG. 6F illustrates a cluster resource group configuration table.
[0025] FIG. 6G illustrates a heartbeat configuration table.
[0026] FIG. 7 is a flow chart summarizing the general steps involved in automatic configuration and semi-automatic configuration of a clustering system in accordance with at least one embodiment of the present invention.
[0027] FIG. 8 depicts a visual configuration diagram that may be presented to the user.
DETAILED DESCRIPTION OF THE INVENTION
Clustering System
[0028] FIG. 1 is a block diagram of a clustering system 100 in accordance with at least one embodiment of the present invention. Here, clustering system 100 is comprised of equipment found in at least two geographically distinct locations 102 and 104 . For example, location 102 may be a metropolitan area such as San Diego, Calif., and location 104 may be a different metropolitan area such as San Francisco, Calif. At location 102 , a management server 106 is responsible for monitoring, configuring, and otherwise managing servers 108 and 110 , network equipment 112 , and storage equipment 113 , 114 , and 115 . Management server 106 , servers 108 and 110 , network equipment 112 , and storage equipment 113 , 114 , and 114 communicate through a local network 116 , forming a local SAN.
[0029] As shown, management server 106 includes a SAN manager 118 that includes a configuration engine 120 and a topology repository 122 . SAN manager 118 also maintains a discovery list 124 , a configuration table 126 , a topology table 128 , and a mapping table 130 , which are discussed in further detail below. SAN manager 118 maintains this information by communicating with various management agents located in servers 108 and 110 , network equipment 112 , and storage equipment 113 , 114 , and 115 . SAN manager 118 and the various management agents may be implemented in software.
[0030] Server 108 may include one or more application programs. These application programs may be server level applications such as Web server applications, network file sharing applications, and others. As FIG. 1 illustrates, server 108 may also include clustering software for maintaining a clustering system, a management agent, and a number of host ports. Server 110 is similarly arranged and may also include one or more application programs, clustering software, a management agent, and a number of host ports.
[0031] Network equipment 112 is illustrated in FIG. 1 as a switch having a number of switch ports. Network equipment 112 also includes a management agent. Network equipment 112 facilitates communication through local network 116 . As shown, network equipment 112 provides communication between servers 108 and 110 and storage equipment 115 .
[0032] Storage equipment 115 may include a number of disk ports, a number of logical volumes 132 , 134 , and 136 , and a management agent. Here, each of the logical volumes 132 , 134 , and 136 may be implemented in different ways, such as by use of various types of redundant array of independent disks (RAID). Each of logical volumes 132 , 134 , 136 may be implemented on a single physical disk (not shown), across multiple physical disks (not shown) within a disk group (not shown), across disks in multiple disk groups, or in some other arrangement.
[0033] Here, server 108 , network equipment 112 , and storage equipment 115 may represent a primary node in a clustering system. For example, server 108 may be executing a database application, using storage equipment 115 to store the associated databases and communicating data to and from storage equipment 115 through network equipment 112 . Fault-tolerance for this database service may be realized by creating a secondary node corresponding to the primary node. Use of equipment located at a geographically distinct location, such as location 104 , would provide effective fault-tolerance because if a catastrophic local event damages equipment at location 102 , redundant equipment at location 104 would be able to provide effective recovery.
[0034] At location 104 , a management server 138 is responsible for monitoring, configuring, and otherwise managing a server 140 , network equipment 142 , and storage equipment 144 . Management server 138 , server 140 , network equipment 142 , and storage equipment 144 communicated through a local network 146 , forming a local SAN. Local SANs at locations 102 and 104 , and perhaps other local SANs, may together form a wide area SAN by communicating over one or more wide area networks 148 .
[0035] As shown, management server 138 includes a SAN manager 150 that includes a configuration engine 152 and a topology repository 154 . SAN manager 150 also maintains a discovery list 156 , a configuration table 158 , a topology table 160 , and a mapping table 162 , which are discussed in further detail below. SAN manager 150 maintains this information by communicating with various management agents located in server 140 , network equipment 142 , and storage equipment 144 . SAN manager 150 and the various management agents may be implemented in software.
[0036] Server 140 may include one or more application programs, clustering software for maintaining a clustering system, a management agent, and a number of host ports. Network equipment 142 is illustrated in FIG. 1 as a switch having a number of switch ports. Network equipment 142 also includes a management agent. Network equipment 142 facilitates communication through local network 146 . As shown, network equipment 142 provides communication between server 140 and storage equipment 144 .
[0037] Storage equipment 144 may include a number of disk ports, a pool 164 of logical volumes, from which logical volumes 166 , 168 , and 170 may be selected, and a management agent. Here, each of the logical volumes in logical volume pool 164 , including logical volumes 166 , 168 , and 170 , may be implemented in different ways, such as by use of various types of redundant array of independent disks (RAID). Thus, each of the logical volumes may be implemented on a single physical disk (not shown), across multiple physical disks (not shown) within a disk group (not shown), across disks in multiple disk groups, or in some other arrangement.
[0038] Here, server 140 , network equipment 142 , and storage equipment 144 may be used to form a secondary node associated with the previously discussed primary node in the clustering system. For example, if the clustering system is designed to provide a secondary node having similar processing, storage, and other capabilities as those of the primary node, it would be desirable to identify a secondary node having similar equipment as the primary node. Server 140 , network equipment 142 , and storage equipment 144 may fit such requirements. The present invention allows equipment such as server 140 , network equipment 142 , and storage equipment 144 to be identified as resources that may be used to form the secondary node.
[0039] Servers 108 , 110 , and 140 are examples of processor devices, storage equipment 115 and 144 are examples of storage devices, and network equipment 112 and 142 are examples of network interface devices.
Information Maintained at Management Server and Elsewhere
[0040] FIG. 2 is an illustration of mapping table 130 maintained in management server 106 of FIG. 1 . Mapping table 130 is illustrated here as an example. Other mapping tables, such as mapping table 162 maintained in management server 138 , may have similar formats. As shown in FIG. 2 , mapping table 130 provides a mapping between application programs being executed and the location(s) of data storage being utilized by such application programs. For instance, an application program executing in server 108 may utilize logical volumes 132 , 134 , and 136 in storage equipment 115 , and mapping table 130 would register such utilization in detail. Different methods may be used to identify the various application programs executing in a particular server. One such method involves using the Common Information Model (CIM) standard, which allows application programs executing in a server may communicate with one another. For example, the management agent in server 108 may use the CIM standard to communicate with, and thereby identify, the various application programs executing in server 108 . Another method involves using repository information maintained by the operating system of the server. For example, the management agent in server 108 may retrieve data from the repository information of the operating system of server 108 to identify various application program executing in server 108 .
[0041] Mapping table 130 is shown to include the following categories of information: ID 202 , Server 204 , Application 206 , Related Mount Point 208 , Related Volume ID 210 , Disk Group (DG) ID 212 , Block Device 214 , Logical Unit (LU) Binding ID 216 , Small Computer System Interface (SCSI) ID 218 , and SCSI Logical Unit Number (LUN) 220 . Here, table 130 indicates that a database (DB) application is executing in Server A (server 108 ). Table 130 further indicates that this DB application is utilizing logical volumes Vol 1 , Vol 2 , and Vol 3 (logical volumes 132 , 134 , and 136 ). For each of these three logical volumes, table 130 provides additional information. Taking Vol 1 just as an example, table 130 indicates the mount point (/u01) at which Vol 1 is associated with, or “mounted” to, the system executing the DB application. Table 130 also indicates the physical disk group (0) and block device (c2t2d1) in which Vol 1 is implemented. In this example, logical volumes are also associated with SCSI IDs, as well as LUNs within particular SCSI IDs. Here, Vol 1 is shown to be associate with a particular SCSI ID (2) and a particular SCSI LUN (1).
[0042] FIG. 3 is an illustration of a LUN binding table 300 maintained in server 108 of FIG. 1 . LUN binding table 300 is illustrated here as an example. Other LUN binding tables maintained in other servers, such as servers 110 and 140 , may have similar formats. LUN binding table 300 indicates the SCSI ID assignment and LUN assignment associated with location(s) of data storage being utilized by application programs executing in server 108 . LUN binding table 300 is shown to include the following categories of information: Binding ID 302 , SCSI ID 304 , LUN 306 , and Inquiry Information 308 . Each Binding ID 302 indicates a particular location of storage and is associated with a particular SCSI ID 304 and a particular LUN 306 . Also, each Binding ID 302 further indicates Inquiry Information 308 , which can provide additional data such as vendor, storage type, and logical volume information. Binding table 300 may be maintained as a part of the operation of the management agent in server 108 . Thus, individual binding tables maintained at various servers, such as servers 108 and 110 , may be used to form the mapping table 130 shown in FIG. 2 .
[0043] FIG. 4A is an illustration of discovery list 124 maintained in management server 106 of FIG. 1 . Discovery list 124 is illustrated here as an example. Other discovery lists, such as discovery list 156 maintained in management server 138 , may have similar formats. As shown in FIG. 4 , discovery list 124 provides a listing of devices available at various locations, such as locations 102 and 104 . Discovery list 124 shows the following categories of information for each device: Local SAN ID 402 , Discovery ID 404 , Device Type 406 , Device Information 408 , IP address 410 , and Area/Global Position 412 . Local SAN ID 402 identifies the local SAN to which the device belongs. Discovery ID 404 identifies a numerical order for the device within its local SAN. Device Information 408 may indicate various information relating to the device, such as vendor and device type. IP address 410 indicates the IP address assigned to the device. Area/Global Position 412 provides information relating to the location of the device, such as name of metropolitan area, longitude, and latitude. Thus, discovery list 124 allows management server 106 to identify available devices at various locations, including distant locations, that may be potential resources suitable to serve as part of a secondary node corresponding a primary node in a clustering system.
[0044] FIG. 4B is an illustration of a functional discovery list 440 that may be maintained in management server 106 of FIG. 1 , in addition to or in place of discovery list 124 . Functional discovery list 440 is illustrated here as an example. Other discovery lists maintained in other management servers may have similar formats. As shown in FIG. 4B , functional discovery list 440 provides a listing of devices available at various locations, such as locations 102 and 104 . Functional discovery list 440 shows the following categories of information for each device: Local SAN ID 442 , Discovery ID 444 , Function Type 446 , and Device Information 448 . Local SAN ID 442 identifies the local SAN to which the device belongs. Discovery ID 444 identifies a numerical order for the device within its local SAN. Function Type 446 provides information on the possible function of the device, such as use in host-based remote mirroring or storage-based remote mirroring. Device Information 448 may indicate various information relating to the device, such as vendor, device type, and device class. Functional discovery list 440 allows management server 106 to identify available devices at various locations, including distant locations, that may be potential resources suitable to serve as part of a secondary node corresponding a primary node in a clustering system.
[0045] FIG. 5 is an illustration of topology table 128 maintained in management server 106 of FIG. 1 . Topology table 128 is illustrated here as an example. Other topology tables, such as topology table 160 maintained in management server 138 , may have similar formats. As shown in FIG. 5 , topology table 128 provides a summary of interconnections over which data may be sent in system 100 . Topology table 128 shows the following categories of information: server information 502 , first local network information 504 , interconnect information 506 , second local network information 508 , and storage information 510 . Topology table 128 depicts the manner by which various networking and storage equipment are linked, including local and wide area network connections. Here, topology table 128 is shown to be focused on storage network topology for purposes of illustration. Other types of topology information may be included as well.
[0046] FIGS. 6A-6G show various configuration tables that may be implemented, individually or in combination, as the contents of configuration table 126 maintained in management server 106 of FIG. 1 . Contents of configuration table 126 is illustrated here as examples. Other configuration tables, such as configuration table 158 maintained in management server 138 , may have similar formats.
[0047] FIG. 6A illustrates a fibre channel switch (FC-SW) zoning configuration table 600 . This table contains categories of information including Zone ID 602 and Switch Port ID List 604 . Zone ID 602 identifies different zones, or groupings of devices, such that devices within a common zone may readily communicate with one another. Switch Port ID List 604 identifies the different network ports which belong to the identified zone. FIG. 6B illustrates a different FC-SW zoning configuration table 606 , similar in structure to table 600 . Zoning configuration tables 600 and 606 allow convenient separation of groups of devices. Here, tables 600 and 606 are described as fibre channel switch zoning configuration tables for purposes of illustration, other types of equipment may also be organized in similar zoning tables.
[0048] FIG. 6C illustrates a storage-based replication configuration table 608 . This table identifies the configuration of storage-based data replication from a set of primary storage locations to a corresponding set of secondary storage locations. Here, the storage system is responsible of maintaining the proper replication of data. Table 608 shows the following categories of information: ID 610 , Group ID 612 , Group Name 614 , primary storage information 616 , secondary storage information 618 , and Cluster Config ID 620 . ID 610 is an entry identifier. Group ID 612 and Group Name 614 relate to the identification number and name for each group of storage resources, such as a group of volumes, representing a storage location. The primary and secondary storage information 616 and 618 each identifies the host and volume information associated with the relevant storage location. Cluster Config ID 620 identifies a label for the cluster corresponding to the primary and secondary storage locations.
[0049] FIG. 6D illustrates a host-based replication configuration table 622 . This table identifies the configuration of host-based data replication from a set of primary storage locations to a corresponding set of secondary storage locations. Here, the host system is responsible of maintaining the proper replication of data. Table 622 shows the following categories of information: ID 624 , Valid 626 , Group ID 628 , Group Name 630 , primary storage location information 632 , secondary storage location information 634 , and Cluster Config ID 636 . Valid 626 relates to whether the particular replication configuration is available. Also, primary and secondary storage location information 632 and 634 are each shown to also include information for identifying the corresponding disk group and block device. Other information in table 622 is similar to information shown in table 608 of FIG. 6C .
[0050] FIG. 6E illustrates a cluster configuration table 638 . This table identifies the arrangement of various clusters in the system, which may include the configuration of physical devices being controlled by cluster software. Table 638 shows the following categories of information: ID 640 , Valid 642 , Cluster ID/Name 644 , Cluster Type/Vender 646 , Member Node List 648 , Heartbeat List 650 , Heartbeat Configuration ID List 652 , Replication Type List 654 , and Replication Configuration ID List 656 . ID 640 identifies a numeric label for each entry, Valid 642 relates to whether the particular cluster is available. Cluster ID/Name 644 provides a number identifier and a name identifier for each cluster presented. Cluster Type/Vendor 646 identifies the classification of the cluster and vendor of the associated equipment. Member Node List 648 identifies the nodes that are members of the particular cluster. Heartbeat List 650 and Heartbeat Configuration 652 relate to arrangement of the heartbeat, which provides a signal that may be used to indicate whether a node, or particular resource at a node, is active. Replication Type List 654 and Replication Configuration ID List 656 relate to the type of replication available and the associated configuration label.
[0051] FIG. 6F illustrates a cluster resource group configuration table 658 . This table identifies the various resources available at different clusters, which may include the configuration of the logical resource group for each node in each cluster. Such resources may be processing, communication, storage, or other types of resources. Table 658 shows the following categories of information: ID 660 , Valid 662 , Cluster Type ID 664 , Resource Group ID 666 , Resource Group Name 668 , Member Node List 670 , Resource List 672 , Replication Type 674 , and Replication Configuration ID 676 . ID 660 provides an numerical label for each entry, Valid 662 relates to whether the particular cluster is available. Cluster Type ID 664 provides an identifier for the cluster and indicates the type and vendor of equipment associated with the cluster. Resource Group ID 666 and Resource Group Name 668 provide a number identifier and a name identifier for each collection of resources associated with the cluster. Resource List 672 identifies the particular resources available within the identified resource group. Replication Type 674 and Replication Config ID 676 relate to the type of replication available and the associated configuration label.
[0052] FIG. 6G illustrates a heartbeat configuration table 678 . This table identifies provides further detail on the arrangement of the heartbeat for each cluster. Table 678 shows the following categories of information: ID 680 , Valid 682 , Cluster Type ID 684 , Heartbeat Type ID 686 , Heartbeat Name 688 , Member Node List 690 , NIC List 692 , and Storage List 694 . ID 680 provides a numerical label for each entry. Valid 682 relates to whether the cluster is available. Cluster Type ID 684 provides an identifier for the cluster and indicates the type and vendor of equipment associated with the cluster. Heartbeat Type ID 686 and HeartBeat Name 688 identify the classification and name of the heartbeat utilized. For example, the heartbeat may be host-based or storage-based. Member Node List 690 identifies the nodes that are members of the particular cluster. NIC List 692 identifies NICs which correspond the to a particular host-base heartbeat. Storage list identifies storage systems which correspond to a particular storage-based heartbeat.
[0053] The information maintained at each management server may be communicated to other management servers. For example, although management servers 106 and 108 are situated at geologically distinct locations 102 and 104 , respectively, they may exchange some or all of the information that is contained in various tables such as those discussed above.
Automatic Configuration
[0054] FIG. 7 is a flow chart summarizing the general steps involved in automatic configuration and semi-automatic configuration of a clustering system in accordance with at least one embodiment of the present invention. The steps shown may be implemented as an integrated routine that allows the selection of either automatic configuration or semi-automatic configuration. Alternatively, the steps shown may be implemented as two separate routines. That is, a system may employ only automatic configuration, or only semi-automatic configuration. For purposes of illustration, FIG. 7 shows the establishment of a clustering system through the formation of a secondary node corresponding to a primary node. Different steps shown in FIG. 7 may be accomplished with use of a user interface, such as an interactive graphical user interface (GUI). Also, the GUI can be situated at any location, as long as the relevant information can be passed to the system. For example, the information submitted through the GUI by the user may be sent to the management server 106 , or to the management server 138 .
[0055] Under automatic configuration, establishment of a clustering system begins with step 702 , in which the primary node of the planned clustering system is identified. This may involve identification, by the user, of the name of one or more target applications and the name of the target server corresponding to the primary node. Alternatively, a more automated process may be employed. For example, the main application executing in a target server may be selected.
[0056] Next, in step 704 , policies for creating the clustering system, including remote mirroring features, may be specified. This step may involve specification by the user of general policies to follow in establishing the clustering system and importance assigned to such policies. For example, the user may be presented with three potential policies: (1) performance, (2) reliability, and (3) cost.
[0057] Performance may relate to the effectiveness of the data transfer between the data storage of the primary node and the data storage of the secondary node, which may involve measures of bandwidth, distance, and network usage in a wide area SAN covering metropolitan areas of San Francisco (SF) and San Diego (SD) are provided in the table below:
[0000]
Network
Type
Total
Usage
SD
Local
2 Gbps
50%
SF-SD
Interconnect
48 Gbps
10%
SF
Local
2 Gbps
8%
[0058] Illustrative measures of bandwidth, distance, and network usage in the same wide area SAN, but from the perspective of the San Diego (SD) metropolitan area, are provided in the table below:
[0000]
Tested
Network
Type
Throughput
Distance
Total
Usage
SF
interconnect
500 Mbps
1000 mile
48 Gbps
10%
[0059] Thus, if a user places emphasis on performance, the secondary node may be chosen to have equal performance as the primary node, in terms of processing capability (server type), storage capability (throughput, cache size, RAID level, etc.), and network interface capability (number and performance of host bus adaptors). Also if there are two or more option for interconnects between the primary device and secondary device, the interconnect that has more available throughput capacity may be chosen. For example, assume there are two interconnects: interconnect A, which has 48 Gbps total throughput capacity and 10% average usage rate (43.2 Gbps available throughput capacity), and interconnect B, which has 128 Gbps total throughput capacity and 80% average usage rate (25.6 Gbps available throughput capacity). Here, interconnect A has more available throughput capacity than interconnect B, so interconnect A may be chosen.
[0060] Reliability may relate to the level of confidence with which the data storage of the secondary node replicates data in the data storage of the primary node. If a user places emphasis on reliability the secondary node may be chosen to have redundant host bus adaptors and highly reliable, enterprise level storage, such as RAID level 1. Cost may relate to the cost of using equipment, such as maintenance costs. Cost may also relate to the cost of acquiring currently unavailable equipment. If a user places emphasis on cost, the secondary node may be chosen to have much lower performance than the primary node, in terms of processing capability (server type), storage capability (throughput, cache size, RAID level, etc.), and network interface capability (number and performance of host bus adaptors). For example, storage equipment of RAID level 5 may be chosen.
[0061] Thus, by specifying general policies such as (1) performance, (2) reliability, and (3) cost, to follow in establishing the clustering system, the user is able control the design of the clustering system, without being required to decipher the detailed considerations relating to technical specifications of related equipment and software. The user may be presented with various general policies from which to choose. The user may specify policies by simply identifying particular policies as important. The user may also specify policies by assigning importance, or weight, to particular policies. This may be done in different ways, such as by user input of ratings, ratios, percentages, or other measures for different policies.
[0062] The next step under automatic configuration is step 706 , in which information on the current system is gathered. Such information may include the contents of mapping tables, discovery tables, topology tables, and configuration tables. This information provides a detailed picture of the various aspects of the current system, including the mapping from applications to resources they utilize, available resource and their configurations, and so on.
[0063] In step 708 , the information on the current system gathered in step 706 is analyzed to select the most appropriate resources and/or arrangements to be used for creating the secondary node. This is done in view of the various policies, and possibly weights assigned to those policies, as defined by the user in step 704 . In step 710 , the selected resources and/or arrangements are presented to the user, and the user is given to opportunity to confirm the selection of resources and/or arrangements. If the user confirms the selection, the process continues with step 712 , discussed below. If the user does not confirm the selection, the process loops back to step 704 .
[0064] In step 712 , the selected resources and/or arrangements are used to create the secondary node. If the selected resources need additional software installation or configuration in order to function properly as the secondary node, such installation or configuration may be performed. Alternatively, the automatic configuration routine or semi-automatic configuration routine may re-select from resources that do not require additional software installation or configuration. Also, default resources that do not require additional software installation or configuration may also be selected in order to avoid such installation or configuration of software. Finally, in step 714 , the configuration table(s) are updated to include information on the secondary node just created.
Semi-Automatic Configuration
[0065] Under semi-automatic configuration, establishment of a clustering system also begins with step 702 , which has been discussed previously. Next, in step 716 , information on the current system is gathered. This step is similar to step 706 discussed above. In step 718 , one or more potential selections of appropriate equipment and/or arrangements to be used for creating the secondary node is presented to the user. The user is given the opportunity to select the various equipment and/or arrangements to be used in creating the secondary node. In step 720 , the user's selection is received and presented back to the user for confirmation. Here, a visual topology diagram such as the one shown in FIG. 8 may be presented to the user. FIG. 8 may also represent a simplified version of block diagram shown in FIG. 1 If the user confirms the selection, the process continues with step 712 , which is has been described previously. If the user does not confirm the selection, the process loops back to step 618 .
[0066] In addition, semi-automatic configuration may also take into account user-defined policies, as is done in the case of automatic configuration. Here, such policies may allow potential selections of equipment and/or arrangements presented to be narrowed, so that the user may be presented with a more focused set of potential equipment and/or arrangements from which to make a selection. Other features discussed above in relation to automatic configuration may be adopted for use with semi-automatic configuration, and vise versa. For example, the visual confirmation diagram discussed in relation to semi-automatic configuration may also be used with automatic configuration, in order to present the automatically selected equipment and or arrangement to the user for confirmation. Further, variations on the different steps shown in FIG. 7 may also be adopted.
[0067] FIG. 1 is a block diagram of a clustering system 100 in accordance with at least one embodiment of the present invention. Such a diagram would allow the user to visually inspect a proposed configuration for a clustering system. This provides an efficient way to present a proposed configuration to the user for confirmation.
[0068] Although the present invention has been described in terms of specific embodiments, it should be apparent to those skilled in the art that the scope of the present invention is not limited to the described specific embodiments. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that additions, subtractions, substitutions, and other modifications may be made without departing from the broader spirit and scope of the invention as set forth in the claims.
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A method, apparatus, article of manufacture, and system are presented for establishing redundant computer resources. According to one embodiment, in a system including a plurality of processor devices and a plurality of storage devices, the processor devices, the storage devices and the management server being connected via a network, the method comprises storing device information relating to the processor devices and the storage devices and topology information relating to topology of the network, identifying at least one primary computer resource, selecting at least one secondary computer resource suitable to serve as a redundant resource corresponding to the at least one primary computer resource based on the device information and the topology information, and assigning the at least one secondary computer resource as a redundant resource corresponding to the at least one primary computer resource.
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BACKGROUND OF THE TNVENTTON
[0001] 1. Field of the Invention
[0002] The present invention relates to a centrifugal type clutch brake device, and more specifically to a novel, improved centrifugal type clutch brake device having a substantially more simplified structure in which a moving means consisting of a screw, pin or the like is provided between a centrifugal clutch housing and a ring-like drive disc of a centrifugal clutch and in which, after the centrifugal clutch is disengaged, the ring-like drive disc is moved axially upwards to effect braking.
[0003] 2. Description of the Related Art
[0004] FIGS. 6 and 7 schematically show how a conventionally used clutch brake device of the type described above is formed according to an existing technique, with the titles of the relevant documents not being disclosed.
[0005] In FIGS. 6 and 7 , numeral 1 indicates a rotation shaft provided on the side of a driving means 2 , such as an engine, and on the upper portion of the rotation shaft 1 , there is provided an actuator plate 4 through the intermediation of a first bearing 3 so as to be rotatable by means of an operation system cable 5 . On the back side of this actuator plate 4 , there is provided an actuator 9 mounted to a plate 6 on the driving means 2 side through the intermediation of a column 7 and a set spring 8 so as to be vertically movable (In FIG. 6 , it is shown in the raised and lowered states, respectively, on the right-hand side and the left-hand side with respect to the center line of the drawing).
[0006] Between recesses 4 a and 9 a of the actuator plate 4 and the actuator 9 , there is provided a ball 10 with a retainer.
[0007] Fixed to the middle position of the rotation shaft 1 is a drive disc 11 substantially in the form of a disc, and the lower portion of this drive disc 11 is equipped with a blade holder 13 through the intermediation of a second bearing 12 , with the blade holder 13 being connected to a driven member, such as a blade (not shown).
[0008] Arranged inside the blade holder 13 is a facing plate 16 urged by a clutch spring 14 and having a facing 15 , with the lower surface of the drive disc 11 and the lower surface of the actuator 9 being capable of coming into contact with and moving away from the facing 15 .
[0009] Next, the operation of this device will be described. The left-hand side portion of the device in FIG. 6 is connected to the operation cable 5 . In the state in which the brake is disengaged and the clutch is engaged, the blade (not shown) connected to the blade holder 13 rotates with the rotation of the rotation shaft 1 , which is driven by the driving means 2 .
[0010] When, in the above-described state, the operation system cable 5 is restored by a brake spring 5 A, the actuator plate 4 rotates, and the ball 10 with a retainer is detached from the recess 9 a . The actuator 9 is lowered as shown on the right-hand side of FIG. 6 and comes into contact with the facing 15 . At the same time, the contact between the drive disc 11 and the facing 15 is canceled, and the rotation of the rotation shaft 1 is not transmitted to the blade holder 13 , with the result that the rotation of the blade holder 13 is stopped.
[0011] The conventional clutch brake device, constructed as described above, has the following problem.
[0012] That is, to rotate and stop the blade holder, it is necessary to rotate the actuator and vertically move the actuator through the ball, resulting in a rather complicated clutch/brake mechanism. Further, a dedicated cable and an operating lever are indispensable to the operation system, resulting in high cost and necessitating novel designing of the apparatus main body.
[0013] As is admitted, a very high level of safety is required of the device. However, since it does not allow post-mounting to a novel/used apparatus, the device has not very much found its way throughout foreign countries, and it is very difficult for the device to meet the recent demand for lower price.
SUMMARY OF THE TNVFNTTON
[0014] It is an object of the present invention to make it possible, through a combination of a centrifugal clutch and a moving means, to automatically engage/disengage a clutch and a brake according solely to the rotation speed of a rotation shaft, without involving any manual operation.
[0015] A centrifugal type clutch brake device according to the present invention includes: a centrifugal clutch shoe fixed to a rotation shaft rotated by a driving means; a centrifugal clutch housing rotatably provided on the rotation shaft through the intermediation of a bearing and forming a centrifugal clutch with the centrifugal clutch shoe; a ring-like drive disc provided at an end of the centrifugal clutch housing through the intermediation of a driving means so as to be axial movable; a driven member connected to the ring-like drive disc; and first and second braking frictional members provided on both sides of a stationary plate provided on the driving means side and capable of coming into contact with the centrifugal clutch housing and the ring-like drive disc, respectively. In the centrifugal type clutch brake device, when, in a state in which the centrifugal clutch is engaged to cause the ring-like drive disc to be rotated through the moving means, a rotating speed of the rotation shaft is reduced and the centrifugal clutch is disengaged to cause the ring-like drive disc to rotate faster than the centrifugal clutch housing; the ring-like drive disc moves to the centrifugal clutch housing side through the moving means; and the ring-like drive disc comes into sliding contact with the second braking frictional member to stop rotating. Further, the moving means includes a threaded portion formed on a lower peripheral surface of the centrifugal clutch housing and an inner threaded portion formed on an inner surface of the ring-like drive disc and threadedly engaged with the threaded portion. Further, the moving means includes at least three pins provided on the ring-like drive disc and a cam lead hole formed in the centrifugal clutch housing and adapted to be engaged with the pins, in which the cam lead hole is formed so as to have an inclination angle θ with respect to a straight line perpendicular to an axial direction of the centrifugal clutch housing. Further, each of the pins has a spherical portion at a distal end thereof.
[0016] The centrifugal type clutch brake device of the present invention, constructed as described above, provides the following advantages.
[0017] Due to the construction in which the moving means consisting of the pin and the cam lead hole is provided between the centrifugal clutch housing of the centrifugal clutch and the ring-like drive disc, the centrifugal clutch being engaged/disengaged according to the rotation speed of the rotation shaft, with the ring-like drive disc being axially moved to engage/disengage the brake, the configurations of the components have been simplified as compared with the conventional construction, and the number of components has been substantially reduced, thereby making it possible to easily achieve a reduction in cost and an improvement in reliability.
BRIEF DESCRIPTTON OF THE DRAWINGS
[0018] In the accompanying drawings:
[0019] FIG. 1 is a sectional view of a centrifugal clutch brake device according to the present invention;
[0020] FIG. 2 is an enlarged main-portion sectional view of FIG. 1 ;
[0021] FIG. 3 is a sectional view of a modification of the device of FIG. 1 ;
[0022] FIG. 4 is an enlarged main-portion sectional view of FIG. 3 ;
[0023] FIG. 5 is an enlarged view of a modification of a main portion of FIG. 3 ;
[0024] FIG. 6 is a sectional view showing a conventional construction; and
[0025] FIG. 7 is a schematic plan view of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] A preferred embodiment of a centrifugal type clutch brake device of the present invention will now be described with reference to the drawings.
[0027] In the drawings, the components that are the same as or equivalent to those of the conventional example are indicated by the same reference numerals.
[0028] In FIG. 1 , numeral 1 indicates a rotation shaft rotated by a driving means 2 , such as an engine or a motor. Fixed to substantially the middle portion of the rotation shaft 1 is a well-known centrifugal clutch shoe 20 (as disclosed, for example, in JP 2003-269495 A). Apart from the one as disclosed in the above-mentioned publication, it is also possible to adopt clutch shoes of various types, such as a well-known trisectional type or a bisectional type using a spring.
[0029] In the portion of the rotation shaft 1 under the centrifugal clutch shoe 20 , there is provided a centrifugal clutch housing 21 through the intermediation of a bearing 12 so as to be rotatable independently of the rotation shaft 1 .
[0030] The centrifugal clutch shoe 20 and the centrifugal clutch housing 21 form a centrifugal clutch 22 , which is engaged/disengaged according to the RPM of the rotation shaft 1 (which, for example, is set to 4000 RPM and 2000 RPM).
[0031] In the outer periphery of the lower portion of the centrifugal clutch housing 21 , there is provided a ring-like drive disc 11 through the intermediation of a moving means 30 so as to be axially movable and capable of undergoing drag.
[0032] Connected to the lower surface of the ring-like drive disc 11 is a driven member 31 consisting of a blade or the like for mowing, etc.
[0033] Between the centrifugal clutch housing 21 and the ring-like drive disc 11 , there is fixedly arranged a stationary plate 6 through the intermediation of columns 32 provided on the driving means 2 side. On the two sides of this stationary plate 6 , there are provided first and second braking frictional members 33 and 34 , and the first braking frictional member 33 is constantly in slight sliding contact with the back surface of the centrifugal clutch housing 21 .
[0034] FIG. 2 is an enlarged schematic view of the main portion A of FIG. 1 , showing how the moving means 30 is formed by a spring.
[0035] That is, formed on a lower peripheral surface 21 b of a lower portion 21 a of the centrifugal clutch housing 21 is a threaded portion 40 , which is threadedly engaged with an inner threaded portion 41 formed on the inner surface of the ring-like drive disc 11 .
[0036] The pitch, number of threads, and lead of the threaded portion 40 are determined so as to facilitate movement while rotating along the axial direction with respect to the centrifugal clutch housing 21 , and are set as appropriate taking into account the weight of the driven member 31 to be mounted.
[0037] Next, the operation of this device will be described. First, when, in the state as shown in FIG. 1 , the driving means 2 is at low speed and the rotation shaft 1 is rotating at low speed, the centrifugal clutch 22 is disengaged, so that exclusively the rotation shaft 1 makes idle running, whereas a running unit, such as a mowing machine (not shown), runs at low speed.
[0038] When, in this state, the accelerator of the running unit is operated in the accelerating direction, the rotation shaft 1 rotates at high speed, and the centrifugal clutch 22 is engaged, with the result that the rotation of the centrifugal clutch housing 21 is transmitted to the ring-like drive disc 11 through the moving means 30 to thereby rotate the driven member 31 .
[0039] In this case, the threaded portion 40 is formed in an inverse thread configuration, so that the ring-like drive disc 11 rotates therewith while somewhat axially lowered with respect to the threaded portion 40 ; in this case, the second braking frictional member 34 and the ring-like drive disc 11 are out of contact with each other, which means the brake is disengaged.
[0040] When, in the above drive state, the rotating speed of the driving means 2 is reduced by operating the accelerator, the centrifugal clutch 22 is disengaged, and the rotating speed of the centrifugal clutch housing 21 is reduced, whereas the ring-like drive disc 11 tends to rotate faster than the centrifugal clutch housing 21 due to the inertia owing to the mass of the driven member 31 ; when the ring-like drive disc 11 rotates faster than the centrifugal clutch housing 21 , even to a slight degree, the ring-like drive disc 11 is brought into the screw-up state with respect to the threaded portion 40 , and the ring-like drive disc 11 is moved somewhat upwards in the axial direction to be brought into sliding contact with the second braking frictional member 34 to engage the brake, thereby bringing the machine to a stop.
[0041] Next, FIGS. 3 and 4 show a modification of the moving means 30 . The components that are the same as or equivalent to those of FIGS. 1 and 2 are indicated by the same reference numerals, and a description of such components will be omitted, the description being focused on the differences.
[0042] In this modification, the moving means 30 are formed by at least three pins 50 provided on the inner surface of the ring-like drive disc 11 so as to protrude inwardly and a cam lead hole 51 formed in the lower portion 21 a of the centrifugal clutch housing 21 .
[0043] The pins 50 are engaged with the cam lead hole 51 , which is, as shown in FIG. 4 , inclined by an inclination angle θ with respect to a radial straight line H perpendicular to the axial direction AX of the rotation shaft 1 and the centrifugal clutch housing 21 .
[0044] Thus, when the centrifugal clutch 22 is engaged, and the ring-like drive disc 11 is rotating, the pins 50 are situated on the lower end 51 a side of the cam lead hole 51 so that the ring-like drive disc 11 is lowered; when the rotating speed of the rotation shaft has been reduced and the centrifugal clutch 22 is disengaged, the pins 50 are situated on the upper end 51 b side of the cam lead hole 51 , and the ring-like drive disc 11 is raised to engage the brake.
[0045] While in the above-described example the pins 50 are formed in a cylindrical configuration, the same effect can also be obtained when, as shown in FIG. 5 , each pin 50 has a spherical portion 52 that is completely spherical or semi-spherical, and this spherical portion 52 is engaged with the cam lead hole 51 . Further, while in the above-described example the driven member 31 consists of a blade, it is also possible to adopt a load other than a blade. Further, the lead of each of the threaded portions 40 and 41 and the inclination angle θ of the cam lead hole 51 are determined by the weight of the driven member 31 , etc.
[0046] The present invention is applicable not only to a mowing machine but widely to various apparatuses, such as go-cart, agricultural machines, machine tools, and construction machinery.
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Disclosed is a centrifugal type clutch brake device in which a ring-like drive disc is caused to move vertically in synchronism with the engagement/disengagement of a centrifugal clutch to thereby engage/disengage the brake, thus attaining a simplification in structure. In the centrifugal type clutch brake device of the present invention, the ring-like drive disc ( 11 ) is connected to the lower portion of a centrifugal clutch housing ( 21 ) of a centrifugal clutch ( 22 ) through the intermediation of a moving device ( 30 ), and the brake is engaged/disengaged in synchronism with engagement/disengagement of the centrifugal clutch ( 22 ).
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates generally to a disk-hub connection and more specifically to disc-hub connectors for utility vehicle disc brakes.
According to the state of the art, disk-hub connections for disk brakes of motor vehicles are constructed either in one piece--that is, the disk and the hub set consist, for example, of one casting--or--see, for example, German Patent Document DE 34 41 304 concerning the above-mentioned type--of two pieces. Because of expansion and crack problems as the result of an intensive heating of the disks during the braking, the one-piece constructions are mainly suitable for lighter motor vehicles. With an increasing trend to use disk brakes also in heavy utility vehicles, the demand exists for a disk construction which can also securely withstand the high stresses occurring during a braking of heavy utility vehicles. Because of a lower tendency to form cracks, the two-piece variant has recently been favored. First attempts to adapt the technology shown in German Patent Document DE 34 41 304 (having the problem of poor ventilation and cooling) to the utility vehicle field are known, for example, from Patent Document WO93/14947. However, the disk shown there can be implemented with respect to manufacturing techniques only at relatively high cost.
In addition to the high requirements concerning the stability with respect to cracks, it is necessary in the case of disk-hub connections for utility vehicles to get by with the scarce available space. In the ideal case, a two-piece construction should not require more installation space than the corresponding one-piece variant.
From German Patent Document DE 34 36 729, as the closest state of the art, a disk-hub connection is known for connecting a brake disk with a hub, particularly for cranes of different types, whose brake disk is provided in the inner peripheral region with semicircular bores or recesses so that "support elements" are formed between the bores which project radially to the inside. On its outer periphery, the hub is also provided with semicircular recesses so that the hub has "cams" on it outer peripheral region which project radially to the outside. In this case, intermediate elements are used for the torque transmission between the hub and the disk as follows: When the hub and the disk are assembled (for example, by shrinking the disk onto the hub), the semicircular recesses of the hub and the disk are in each case situated opposite one another so that circular recesses are formed between the hub and the disk. Sleeves are inserted into these recesses, which sleeves are axially secured by screws and washers. Although it is possible in this manner to partly eliminate excessive strains result from temperature differences between the hub and the disk, the mounting of the disk remains relatively complicated. The solution is also hardly suitable for transmitting the high braking forces occurring in the case of faster utility vehicles.
In contrast to this state of the art, it is an object of the invention to provide a hub-disk connection which ensures a secure force transmission between the hub and the disk and can easily be mounted also in a narrow installation space.
The invention achieves this goal by a disk-hub connection in the case of which the torque transmission between the disk and the hub during braking from a forward drive and a reverse drive is always fully ensured. In the case of which, because of the uncoupling of the disk and the hub, crack formations caused by the heating of the disk during the braking operation are safely prevented. Furthermore, a disk-hub connection is implemented at reasonable cost whose components can be produced also without high-precision manufacturing tolerances and which can be assembled in an easy and rapid fashion. Another advantage of the invention is the fact that it does not increase the installation measurements of the disk-hub complex in comparison to a one-piece variant.
The use of additional elements between the disk and the hub, which also contribute to the torque transmission between the brake disk and the brake hub, is basically known (for example, from German Patent Document DE-OS 38 14 614 concerning rail vehicle technology), in the field of rail vehicle technology. But of the clearly lower frictional connection between the wheel and the rail, the braking torques are much lower than in the utility vehicle field. Thus, in the case of a multi-part construction of the hub and the disk, the bolts connecting the disk and the hub can also contribute to the transmission of the torque. For this reason, among others, only three intermediate sliding block elements are used in the case of the brake disk of German Patent Document DE OS 38 14 614. In contrast, because of the engagement of the cams of the hub in the intermediate element, the present invention makes it possible to also transmit larger torques securely and without the danger of breakage. The intermediate element implements a form closure and frictional connection which permits an unlimited secure transmission of the forces and torques between the disk and the hub which occur during the braking operations.
A preferred variant of the invention is characterized in that the intermediate elements engage in the supporting elements and are supported in the peripheral direction in a form-locking manner on the support elements. The variant of the invention implemented in this fashion further optimizes the torque transmission from the hub to the disk while simultaneously minimizing the required installation space because the cams, the intermediate elements and the wheel hub projection each engage in one another in a particularly space-saving manner.
In the case of another, particularly preferred embodiment of the invention, the intermediate elements have lateral projections which are supported in the axial direction on the support elements. In addition to taking over the task of the torque transmission in the radial direction, the support elements therefore advantageously also take over the required axial fixing of the disk on the hub.
Another advantage of the invention is the result of the fact that, because of the intermediate piece, it is possible to design the support surfaces such that the hub and the disk can be manufactured of different materials, which leads to further savings of weight and cost.
In the following, the invention will be described in detail with reference to the drawing. Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a disk-hub connection according to the invention;
FIG. 2 is a sectional view along Line B--B from FIG. 1;
FIG. 3 is an enlargement of a cut-out of FIG. 2;
FIG. 4 is a sectional view along Line A--A from FIG. 1;
FIG. 5 is a sectional view of another embodiment of the invention corresponding to FIG. 4;
FIGS. 6a-c are a top view and sectional views of another embodiment of the invention.
First, the embodiment of FIG. 1 will be described.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a disk-hub connection 1 according to the invention for connecting a brake disk 2 with a hub 3 for a (not shown) utility vehicle disk brake.
As illustrated in FIG. 2, the brake disk 2 has two friction surfaces 5, 6 which are connected with one another by webs 4. As shown in FIGS. 1 and 4, pairs of support elements 7 are molded to the friction surfaces 5, 6 in the interior peripheral region in each case toward the inside.
The disk hub 3 (here, a cylindrical tube-shaped section on whose one end the disk 2 is placed and whose other end can be screwed on the actual wheel hub) is provided with cams 8 on its outer periphery. The cams each project radially to the outside. The cams 8 engage in intermediate or force transmitting elements 9. The intermediate elements 9, turn, are supported in both peripheral directions in a form-locking manner on one pair of support elements 7 respectively. This ensures, in both rotating directions, a secure torque transmission from the disk 2 by way of the intermediate element 9 to the hub 3. In particular, the torque transmission is ensured during braking operations from the forward drive as well as in the case of braking operations from the reverse drive. On their sides facing the cams 8, the lateral surfaces of the support elements 7 are aligned in parallel to the radial line of the disk, while the exterior sides of the support elements 7 facing away from the cams 8 for increasing the protection against breakage, extend in a very sloped manner with respect to the radial line. In the embodiment of FIG. 1, a total of five double pairs of support elements 7 and five of the cams 8 are provided, which are each arranged to be offset with respect to one another by 72°.
For the axial securing, lateral projections 10, 11 are molded to the intermediate elements 9 and reach in the peripheral direction between the support elements 7 of the friction surfaces 5, 6 which each belong together in pairs. Thus, the securing of the connection between the hub 3 and the disk 2 is also clearly improved in the two axial direction with respect to the state of the art.
During the mounting, the intermediate elements 7 are first slid from the inside radially toward the outside into the disk 2. The disk 2, which is prepared in this manner, is then placed laterally or axially on the hub 3 so that the cams 8 of the hub 3 reach into the intermediate elements 9. For the axial fixing, the cams 8 and the essentially U-shaped intermediate elements 9 are each connected with one another by way of a stud or fastener 12. As the result, the support elements 7 are displaceable only in the radial direction toward to the outside relative to the intermediate elements 9. In which case, the support areas between the support element 7 and the intermediate element 9 have a surface-shaped construction. The intermediate elements 9 correspondingly have support surfaces in their interior area, on which support surfaces the cams 8 of the hub 3 are supported in the peripheral direction. Because of the radial displaceability of the intermediate elements 9 with respect to the disk 2, crack formations of the disk 2 are safely prevented.
The intermediate elements 9 are preferably manufactured from a high-strength material having a low thermal conductivity (such as a ceramic material or a lower-heat-conducting steel). Because of their simple construction, it is even possible to construct the intermediate elements 9 such that they can be manufactured as a section of a bar.
In another embodiment of the invention--illustrated in FIG. 5--, the support surfaces of the intermediate element 9 have a conical construction, which securely ensures a demounting even after a long operation under rough conditions.
FIG. 6 shows another embodiment of the invention in which the hub is constructed as a reasonable-cost deep-drawn part. This exhibits another important advantage of the invention wherein the disk 2 and the hub 3 may not--as otherwise customary--be manufactured of gray cast iron but of different materials. This is possible, among other things, because the non-elastic intermediate element (which is manufactured, for example, of high-strength steel) makes it possible to design the surfaces required for the force transmission to be from a lower-value material (for example, of the hub) to a higher-value material (in this case, of the disk). For connecting the hub 3 and the stud 12 as well as optionally also for the additional supporting of the hub 3, in the case of the embodiment of FIGS. 6a-c, an additional insertion piece 13 is inserted into the hub 3. Advantages of the construction as a deep-drawn hub are further savings of cost and weight in comparison to a cast hub.
Although the present invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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The invention concerns a disc-hub connection for connecting a brake disc to a hub, in particular for utility vehicle disc brakes. In its inner peripheral region the brake disc comprises support elements, the hub comprising cams in its outer peripheral region. Intermediate elements are used to transfer torque from the cams of the hub to the support elements of the disc, the cams of the hub engaging in the intermediate elements and the latter engaging in the support elements.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates to an apparatus and a method for removing fasteners from sets of documents.
Such an apparatus and such a method are known from U.S. Pat. No. 4,090,690.
It is noted that fasteners to be removed occur in a large variety, as in the form of staples with a bridge part and two bent legs, eyelets, metal plates which are bent over a corner of a document, and split pins which, in fitted condition, have a button resting against the set of documents.
The apparatus and method according to U.S. Pat. No. 4,090,690 constitute an improvement over the destaplers known heretofore, especially for rapidly removing large numbers of staples, because the laborious hooking of the fastener and then pulling it away relative to the documents have been replaced by a single operation, whereby at least a portion of the staple is pressed into the set of documents.
However, a drawback of this known destapler is that a staple, after it has been pressed into the set of documents, must still be separated from the documents. A further drawback of this known destapler, and the method to be practiced with it, is that the staples cannot be pressed through sets of documents of a thickness more than twice the wire thickness of the staple. Further, in many cases, the fastener tilts during compression, so that the maximum thickness of a set of documents through which a staple can be pressed is limited to a set of documents having a compressed thickness less than a single time the wire thickness of a fastener.
SUMMARY OF THE INVENTION
The object of the invention to provide a solution to the problem of removing fasteners very fast and reliably from sets of documents.
According to the present invention, this object is realized by providing an apparatus for removing fasteners from sets of documents, which comprises a perforator for perforating a set of documents closely along at least a portion of a fastener to be removed. A further embodiment of the invention for realizing this object is formed by a method for removing fasteners from sets of documents, wherein the set of documents is perforated along at least a portion of the fastener to be removed.
By perforating the set of documents from which the fastener is to be removed, a passage right through the set of documents is created in a simple and reliable manner, so that the fastener can be simply removed. The perforation provided in the set of documents when removing the staple may be of a very minor size and does not constitute any essentially greater damage of the documents than the weakening of the documents and the creases and dog-ears formed in the conventional removal of fasteners. Generally, next to the perforation, sufficient space is left for fastening the documents to each other again, if desired. In general, it is advantageous if the perforation extends as closely as possible alongside the staple. Perforating directly alongside the staple is most ideal, but it is also possible to select distances between the position of this fastener to be removed and the most proximal edge portion of the perforation to be less than 1, 2, 3 mm or slightly more.
Hereinafter, further objects, embodiments, effects and advantages of the invention are described and explained on the basis of a presently most preferred exemplary embodiment and a few variants, with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a destapler according to the invention;
FIG. 2 is a cut-off, perspective representation of a punch-die plate combination for use in an apparatus according to FIG. 1;
FIG. 3 is a sectional side elevation of the punch-die plate combination according to FIG. 2;
FIG. 4 is a cut-off top plan view of a punch of a destapler according to a further exemplary embodiment in a condition of use above a staple in a set of documents;
FIG. 5 is a sectional side elevation along the line V-V in FIG. 4;
FIG. 6 is a sectional side elevation along the line VI-VI in FIG. 4, albeit that the punch is shown in a condition pressed through the set of documents;
FIG. 7 is a sectional cut-off side elevation of a destapler according to a still further exemplary embodiment in a condition of use just before the perforation of a set of documents;
FIG. 8 is an elevation similar to FIG. 7, in a condition of use in which the set of documents has just been perforated;
FIG. 9 is a sectional cut-off side elevation transverse to the elevation according to FIG. 8;
FIG. 10 is a sectional cut-off side elevation of a destapler according to a yet further exemplary embodiment in a condition of use just before the perforation of a set of documents;
FIG. 11 is a schematic representation of a sensor for detecting the position and the orientation of a staple; and
FIG. 12 is a cutaway side elevation of a destapler with automatic positioning of the destapling perforator.
DETAILED DESCRIPTION
The following description is based on examples intended for removing staples consisting of wire material forming a bridge part and bent legs, projecting from that bridge part. However, it will be clear to those skilled in the art that adapted embodiments can also be used for removing other types of permanent fasteners provided through documents or embracing them.
FIG. 1 shows, by way of example, a stapler based on a commercially available stapler of the make Rapid, type “2”, manufactured by Isaberg AB of Hestra, Sweden, with an underframe 1 , a reciprocable supporting arm 2 which can be pivoted back and forth relative to the underframe 1 about an axis 3 . Naturally, as a basic structure, any other stapler or a specially constructed stapling machine having a sufficiently stable construction can be used.
In a manner which is known and therefore not further described here, the supporting arm 2 is provided with a mechanism 4 for providing staples through sets of documents.
The apparatus further comprises a perforator 5 with a die or punch 6 and a die plate 7 . The supporting arm 2 further carries a punch member 6 of perforator 5 and the underframe 1 carries the die plate member of the perforator 5 .
The mechanism 4 for providing staples has an operating knob 8 which is mounted on a transmission slide 9 . In conventional use, upon depression of the operating knob 8 , the slide 9 is moved down and a staple is shifted off a row of staples and pressed into a set of documents which is held between the supporting arm 2 and the underframe 1 . To block the transmission slide 9 in its upper position, the mechanism 4 for providing staples comprises a blocking pawl 10 which is operable by a sliding knob 11 . When the sliding knob 11 is in the “STAPLE” position, the transmission slide 9 is released, allowing it to reciprocate in a conventional manner for providing staples. When the sliding knob 11 is in the “DESTAPLE” position, the transmission slide 9 is blocked, allowing the operating knob 8 to be pressed upon for perforating (piercing) paper in the area of a staple without the stapling mechanism 4 dispensing and placing a new staple.
The construction and the operation of the perforator is described in more detail with reference to FIGS. 2 and 3, which represent the embodiment of perforator 5 that is presently preferred most.
In FIG. 3, the perforator 5 is represented with a set of documents 12 , fastened to each other by a staple 13 , placed between the punch 6 and the die plate 7 . The punch 6 forms a projection for perforating the set of documents 12 and, as the set of documents is being perforated, for engaging, through the perforation provided, the staple 13 to be removed, which is thereby pressed, ahead of the punch 6 , through the Set of documents 12 .
More particularly, starting from the situation shown in FIG. 3, first the punch 6 is moved down, causing the set of documents 12 to be perforated and portions of the documents in which the staple 13 is provided to be cut loose from surrounding material. In the process, the staple 13 and any adjacent material of the set of documents 12 are temporarily received in a recess 14 in the punch 6 , while a schematically indicated resilient element 15 engages the staple and thereby exerts a pressure force on the staple 13 in the direction of movement of the punch 6 . As soon as the perforation of the set of documents 12 is complete and the staple 13 has been cut loose completely from the documents 12 , the staple 13 is ejected by the resilient element 15 through an opening 16 in the die plate 7 and a portion 17 of the subjacent underframe 1 .
It is also possible to make the recess 14 in the punch 6 considerably less deep, for instance just deep enough to keep the staple 13 in front of the punch 6 . In that case, during the perforation of the set of documents 12 , the staple is pressed ahead of the punch 6 , which requires a higher punching force but enables a simple construction of the punch and limits the risk of the staple getting stuck in the recess in the punch.
The die plate 7 has an elongate opening for receiving and passing a staple to be removed. This provides the advantage that the staple can be punched loose and separated in a single movement. It is also possible, however, to have a punch run against a counterplate and, for instance, to eject the staple by moving the punch together with the set of documents away from the counterplate.
The opening 16 in the die plate 7 , located opposite the punch 6 , further facilitates accurate positioning of the staple 13 , in that the opening 16 in the die plate 7 further functions as a positioning recess into which falls the staple portion remote from the punch, projecting from the set of documents 12 . When positioning the set of documents 12 , it is thus clearly felt whether or not the staple 13 is properly positioned. Furthermore, arresting the staple in the opening 16 facilitates keeping the staple 13 exactly in its position opposite the punch 6 during punching.
For an accurate positioning of the staple 13 , it is further advantageous that the opening 16 in the die plate 7 is shaped to correspond with the cross section of the punch 6 . If the portion of the staple 13 remote from the punch 6 , projecting outside the documents 12 , falls into the opening 16 , the staple is thus reliably positioned in the punching path of the punch 6 at all times.
FIGS. 4-6 represent an alternative embodiment of a perforator 55 for a destapler according to the invention, each time in combination with a set of documents 62 and a staple 63 to be removed therefrom. The perforator 55 has a punch 56 and a die plate 57 with an opening 66 . The punch 56 has an end face 68 which forms a profile in the form of a channel-shaped recess, traversing the end face, for receiving a portion of a staple 63 . A central portion 69 of the opening 66 of the die plate 57 corresponds to the shape of the cross section of the punch 56 . Peripheral portions 70 of the opening 66 of the die plate 57 on opposite sides of the central portion 69 are open when the punch 66 is in a position projecting into the die plate 57 . Other profiles, such as a serration or a pair of projecting parts, may also be used to keep the staple opposite the end face during removal.
In the use of such a perforator 55 , the perforation is provided by the punch 56 between arms 71 of the staple 63 . Each time the punch 56 has been pressed through the set of documents 62 , the punch 56 engages a bridge portion 72 of the staple 63 . This stage of the process of removing a staple is shown in FIG. 6 . Finally, the punch 56 presses the staple 63 out of the set of documents 62 , causing the arms 71 to bend slightly to a position transverse to the plane in which the set of documents 62 extends. The channel-shaped recess extending transversely across the end face of the punch 56 here ensures that the bridge portion 72 of the staple 63 , as it is being pressed away, remains opposite the punch 56 and does not slide laterally off the end face of the punch 56 . A particular advantage of this perforator is that it does not need to be oriented relative to the staple to be removed, at least when the opening in the die plate allows the passage of staples regardless of the orientation in the plane of the set of documents.
Since the central portion 69 of the opening 66 in the die plate 67 is wider than the peripheral portions 70 of that opening 66 , a punch 56 can be used which is wider than the staple 63 , while the staple 63 , owing to the narrow peripheral portion 70 , is accurately centered, especially in its transverse direction, relative to the punch 56 , and the punch 56 reliably engages centrally of the staple 63 . Further, the narrow design of the outer portions 70 of the opening 66 limits bulging of the documents.
FIGS. 7-9 represent another alternative embodiment of the perforator 105 . This perforator 105 is provided with knives 123 for cutting through a set of documents 112 along a staple 113 to be removed. By cutting along a staple 113 to be removed, and removing the cut-loose staple 113 from the set of documents 112 , the amount of material that is removed from the documents 112 is kept very low. If cutting is limited to a single cut along the staple, the amount of cut-loose material can even be limited to substantially zero.
According to the present example, however, two knives 123 are used, which are suspended to cut on opposite sides along a staple 113 to be removed. Thus, the staple 113 can be cut loose highly reliably.
The knives 123 are suspended so as to converge in a cutting direction (arrow 124 ), causing them, during cutting, to push towards the staple 113 and slide along the staple 113 . As a result, cutting proceeds very closely along the staple 113 and cuts are obtained which, practically speaking, communicate with the holes provided in the set of documents 112 when the staple 113 was applied, so that the staple 113 is cut loose completely, or substantially completely, from the set of documents 112 .
The knives 123 have fixed ends 125 which are suspended so as to be movable relative to each other, transversely to the cutting direction 124 and the cutting edges 126 . To that end, a knife holder member 127 which is reciprocable along with the knives 123 in the cutting direction 124 , is provided with a slot 128 , transverse to the cutting direction, in which slot guide slides 129 carrying the fixed ends 125 of the knives 123 can be reciprocated. Due to the displaceability of the fixed ends, the angle between the knives 123 can be gradually reduced during the movement in the cutting direction 124 , so that, even when perforating thicker packs of documents 112 , the distance between the cuts on the side of the packs of documents 112 proximal to the knives 123 is limited, and tearing of the documents between the cuts is prevented.
The guide slides 129 are further guided in slots 130 in a fixed portion 131 of the knife holder. These slots 130 converge in the shape of a V in the cutting direction 124 , so that during the performance of a perforation stroke, an imposed movement of the fixed ends 125 of the knives is obtained, with the mutual distance between them decreasing according as the knives 123 move further in the cutting direction 124 . As a result, the knives 123 always move substantially in the direction in which they project, so that tearing of documents is prevented.
For limiting damage to the set of documents 112 , it is further advantageous that the knives 123 are of flexible design, so that they can adjust to the documents 112 . This further provides the advantage that the knives 123 , from the fixed ends 125 , can be pressed obliquely against a side of a staple 113 , but alongside the staple 113 can extend virtually parallel to the legs of the staple. This enables reliably making cuts that extend very closely along the staple throughout their height.
As appears from FIG. 9, the cutting edges 126 each have a central portion 132 and outer portions 133 , the central portion 132 projecting relative to the outer portions 133 in the cutting direction 124 . Such a design of the cutting edge 126 limits the cutting forces. In combination with the position of the knives 123 projecting obliquely towards the staple 113 , this design of the cutting edge 126 further makes it possible for the central portion 132 of the cutting edge 126 to cut inside the space enclosed by the staple 113 , while the outer portions 133 of the cutting edge 126 are guided by the legs of the staple 113 , extending through the documents 112 .
Optionally, it is possible to further use the central portion 132 of the cutting edge 126 , while engaging the bridge portion 124 of the staple 113 , to press the staple from the documents 112 . However, for displacing the staple 113 , it is preferred to use stop surfaces 135 facing in the cutting direction 124 for carrying along a staple 113 to be removed. This prevents contact between the cutting edge 126 and the typically steel staple 113 , so that the cutting edge 126 remains sharp longer.
According to the example shown, the stop surfaces 135 of the knives 123 engage the portions of the staple 113 that are proximal to the knives 123 prior to cutting. It is also possible, however, to arrange for such stop surfaces carried by the knives to engage another portion of the staple, such as the bridge portion.
In the perforator 105 according to this example, too, the documents 112 are supported in the area of the staple 113 by a die plate 107 with an opening 116 , through which opening 116 the staple 113 passes after being separated from the documents 112 .
FIG. 10 shows a still further exemplary embodiment of the perforator 155 for perforating a set of documents to remove a staple therefrom. The perforator 155 has two punches 156 of a cross section slightly greater than the cross section of the wire material of which the staples to be removed consist. Located opposite the punch dies 156 is a die plate 157 with an opening 166 , in which the dies 156 fit with a very minor lateral clearance, and through which fit portions of the staple 163 . The punch dies 156 are represented in solid lines in a position immediately prior to the cutting of the staple and the perforation of the set of documents 162 . Broken lines indicate the punch dies 156 in an extreme projecting position. To remove a staple 163 , the punch dies 156 are displaced from the starting position in the cutting direction towards the extreme projecting position. This causes the staple to be cut first adjacent two corner points between portions extending through the set of documents and portions extending along the set of documents. Then, two cut-loose portions of the staple 163 , including the portions extending through the set of documents, are pressed away, ahead of the punch dies 156 , out of the set of documents 162 , while the punch dies 156 perforate the set of documents 162 . These cut-loose portions leave the set of documents 162 through-the opening 166 in the die plate 157 .
Since the punch dies 156 have a slightly greater diameter than the wire of the staple 163 , the portions of the staple 163 extending through the set of documents 162 are reliably cut loose and propelled.
To accurately position the punch dies 156 relative to the staple to be cut, on the side of the documents 162 where the punch dies 156 are located in the initial position, a template 186 with a recess 187 is pressed against the set 162 . The staple then falls into the recess 187 , so that the position of the staple 163 with respect to the punch dies 156 is defined. The end faces of the punch dies 156 are provided with a profile ensuring that the out-off portions of the staple are held in front of those end faces during the press-away operation. That profile may be designed, for instance, as a concave surface.
The residual portion of the staple 163 on the side of the template 186 can be removed in various ways, for instance by a blower or a stiff brush.
FIGS. 11 and 12 show an apparatus according to an embodiment of the invention which is presently preferred most as to its general construction. This apparatus comprises a sensor 235 for detecting the position of a staple to be removed, and transport means for displacing a set of documents and the perforator 205 relative to each other, such that the perforator 205 is aligned with the detected position of the staple in the set of documents for providing the perforation in the area of the priorly detected position of the staple.
The transport means formed by a transport path 236 , along which are arranged driven and mutually coupled rollers 260 and carriages 241 , 242 which are mobile along rails 243 , 244 , transversely to the transport path 236 .
Prior to the removal of a staple, the set of documents is scanned for detecting the position of the staple to be removed. Then the documents are displaced along transport path 236 and the perforator 205 is displaced transversely to the transport path until they are displaced relative to each other, such that the perforator is disposed opposite the staple to be removed. The documents can now be reliably perforated in the area of the staple for removing the staple.
The drive unit 245 for driving the transport rollers 237 , 238 , 239 , 240 is connected to a control unit 247 via a line 246 . Further, the sensor 235 is connected to the control unit 247 via a line 248 .
The position of the staple is determined on the basis of the displacement of the documents along the transport path 236 prior to the detection of the staple and on the basis of the position in the direction transverse to the transport path, where the staple is detected. Then the document is displaced over a fixed distance along the transport path 236 and the carriages 241 , 242 are displaced along the rails 243 , 244 into a position corresponding to the position of the staple in transverse direction relative to the transport path 236 .
The upper carriage 241 is coupled to a toothed belt 249 which passes over gears in end parts 250 on opposite sides of the rail 243 . The lower carriage 242 is clamped with some friction in the rail 244 . For displacing the carriages 241 , 242 equally, first the punch 206 of the perforator 205 is set in a position in which it projects into the opening 216 in the die plate 207 . To that end, the entire rail 249 , including the end parts 250 , is moved down relative to the frame 251 of the apparatus. The drive for this can be designed in a manner known per se, for instance with electromagnets which may or may not be enhanced by levers or the like, and is therefore not further described. With the punch 206 in this position, the carriage 241 is displaced and the carriage 242 is carried along.
For operating the perforator 205 , the control unit 247 is coupled via a line 252 to the drive (not shown) of the perforator, which drive is mounted on the frame 251 . To control the position of the carriages 241 , 242 in transverse direction, the control unit 247 is coupled via a line 253 to the drive (not shown) of the toothed belt 249 .
To avoid friction during the displacement of the carriage 242 , it may optionally be provided with friction members engaging the rail 244 , which can be set out of operation.
It is possible that the position of the staple is such that the set of documents is already disposed between the punch 206 and the die plate 207 before the staple has reached the sensor 235 and the perforator 205 can be set in the proper position in transverse direction. For such situations, it may be provided that the documents are first transported back automatically to clear the area of the perforator 205 and then, after the perforator 205 is set in the desired position in transverse direction, to transport the documents along the transport path 236 , such that the staple is brought opposite the perforator 205 . Renewed detection of the staple as it passes the sensor 235 again may then be utilized for the accurate control of the transport of the documents. If the documents are introduced with the staple in a leading portion, return transport of the documents will generally not be necessary.
The perforator 205 is additionally suspended for pivotal motion about an axis 254 in the cutting direction 224 . During the scanning of the set of documents, further the orientation of the staple to be removed is detected and subsequently the perforator 205 is moved relative to the set of documents into an orientation corresponding to the orientation of the staple. To that end, the punch 206 and the die plate 207 are suspended for pivotal motion about said axis 254 , and the punch is mounted in a rotatably suspended carrier 227 which is coupled by a toothed belt 255 to a gear on an output shaft of a stepping motor 256 . The stepping motor is connected to the control unit 247 via a line 257 .
The sensor 235 for detecting the position of the staple is designed as a conductivity sensor. By scanning at which points a set of documents transmits a voltage, it can be determined in a simple manner where the typically metal staple is located.
The depicted sensor 235 comprises a number of detectors 258 in the form of scanning wheels, distributed in a direction transverse to the direction of transport of the documents. The scanning wheels 258 are represented schematically in FIG. 11, and for clarity only two of them are designated by reference numerals. The voltage is applied to the upper scanning wheels 256 . Failure of the voltage on lower scanning wheels marks the arrival of a leading edge of a set of documents at the location of the sensor 235 . Thereupon, voltage on one or a few of the lower wheels 258 indicates that a staple is located between those wheels. By monitoring which of the lower wheels 258 are subject to a voltage, and registering the position of the documents in the direction of the transport path, the position and the orientation of the staple or staples can be accurately determined.
Then, as regards the position of the staple in the direction of transport, it is sufficient to transport the documents over a fixed distance to the perforator 205 to bring the staple exactly to the location of the perforator 205 .
Within the framework of the proposed concept, naturally many variations are conceivable. Thus, the perforator may, for instance, be mounted in a fixed position with respect to a conveyor, while the documents are displaceable over the conveyor in the x- and y-directions. Such conveyors are described in U.S. Pat. Nos. 5,222,585 and 5,415,266.
For determining the position of the staple, too, various alternative sensors are possible, based on principles for metal detection, known per se, such as a combination of a magnetizer for magnetizing the staple and a sensor sensitive to magnetism, or a combination of an antenna for generating an electromagnetic field and facilities for detecting energy locally absorbed from the field generated. Also various mechanical sensors can be used, such as a ridge for engagement of a staple butting against that ridge, or a thickness sensor. Further, the detection can be carried out in an optical manner, as by the detection of a dispersion characteristic of a metal staple and/or reflection of light of one or more wavelengths, while the light source may be a laser unit producing a line-shaped or planar light beam which is moved along the documents. Such scanners are known per se. Another example of a suitable sensor for determining the position of the staple is a pressure-sensitive film which is pressed against the set of documents by a flat support. Such a film is commercially offered by, for instance, Tekscan, South Boston, Mass., United States.
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Apparatus for removing fasteners ( 13; 63; 113; 163 ) from documents ( 12; 62; 112; 162 ) with a perforator ( 5; 55; 105; 155; 205 ) for perforating documents ( 12; 62; 112; 162 ) in the area of the fastener to be removed, wherein the means for separating from the set of documents ( 12; 62; 112; 162 ) the fastener to be removed ( 13; 63; 113; 163 ) are constructed as a perforator for perforating the set of documents closely along the fastener to be removed. Also disclosed is a method for removing fasteners ( 13; 63; 113; 163 ), wherein the fastener ( 13; 63; 113; 163 ) is separated from the documents ( 12; 62; 112; 162 ) simply and fast in a single operation by perforating the set of documents ( 12; 62; 112; 162 ) closely along the fastener to be removed ( 13; 63; 113; 163 ).
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RELATED APPLICATIONS
[0001] This application is a continuation under 37 C.F.R. 1.53 (b)(1) of pending U.S. patent application Ser. No. 10/797,949, filed Mar. 10, 2004, which claims the benefit of issued U.S. Pat. No. 6,729,534, which is a continuation of issued U.S. Pat. No. 6,536,657, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/306,757, filed Jul. 20, 2001, by the same inventors and having common assignee, the contents of the prior pending application, two patents, and provisional application being incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to container blanks and more particularly to a blank for a disposable thermally insulated container such as a paper cup.
BACKGROUND OF THE INVENTION
[0003] Disposable paper cups with heat insulating capability are a desirable and widely used commodity. These types of cups are designed for hot liquid contents such as hot coffee/tea/chocolate and tend to maintain the liquid contents' temperature by preventing undesirable heat transfer from the hot liquid contents inside the cup to the cup holder's hand hoeing the cup. These cups may also be used for cold liquid contents in which case the insulated walls of the cup help maintain the cold liquid contents' temperature by preventing undesirable heat transfer from the cup holder's hand to the cold liquid contents.
[0004] Thermally insulated cups come in various known configurations. For example an insulated cup is disclosed in Amberg et al (U.S. Pat. No. 3,737,093) which uses a plastic cup placed within a paper cup to create air space therebetween for thermal insulation purposes. Another insulated cup is disclosed by Iioka (U.S. Pat. No. 4,435,344) which coats a paper cup with a thermoplastic synthetic resin film which is subsequently heated to form a foamed insulating layer. Neale et al (U.S. Pat. No. 5,952,068) deals with a cup insulation layer formed from syntactic foam, a type of foam which incorporates insulating particles held in place by a binder. The insulating particles may contain an air space.
[0005] None of the known insulated cups, however, is an effective thermal insulator. Furthermore, none of the known insulated cups can be manufactured at low cost on a wide scale due to complexity of fabrication, high cost of materials, and the like.
SUMMARY OF THE INVENTION
[0006] The present invention is generally directed to a container blank comprising at least one substrate layer made of disposable material and at least one film layer disposed substantially over the substrate layer and having at least one portion adapted to shrink away from the substrate layer upon application of heat. The shrunk film layer portion is adapted to thermally insulate the substrate layer located substantially behind the shrunk film layer portion.
[0007] These and other aspects of the present invention will become apparent from a review of the accompanying drawings and the following detailed description of the preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is generally shown by way of example in the accompanying drawings in which:
[0009] FIG. 1A is a side plan view of a first disposable insulated cup blank comprising shrink film which is pattern adhered to a paperboard substrate in a first sealing pattern in accordance with the present invention;
[0010] FIG. 1B is a partially cut away front perspective view of a disposable insulated cup formed from the blank of FIG. 1A in accordance with the present invention;
[0011] FIG. 1C is a cross sectional view taken along line 1 C- 1 C of FIG. 1B ;
[0012] FIG. 2A is a plan view of a second disposable insulated cup blank comprising shrink film which is pattern adhered to a paperboard substrate in a second scaling pattern in accordance with the present invention;
[0013] FIG. 2B is a partially cut away front perspective view of a disposable insulated cup formed from the blank of FIG. 2A in accordance with the present invention;
[0014] FIG. 2C is a cross sectional view taken along line 2 C- 2 C of FIG. 2B ;
[0015] FIG. 3A is a plan view of a third disposable insulated cup blank comprising shrink film which is pattern adhered to a paperboard substrate in a third sealing pattern in accordance with the present invention;
[0016] FIG. 3B is a partially cut away front perspective view of a disposable insulated cup formed from the blank of FIG. 3A in accordance with the present invention;
[0017] FIG. 3C is a cross sectional view taken along line 3 C- 3 C of FIG. 3B ;
[0018] FIG. 4A is a plan view of a fourth disposable insulated cup blank comprising shrink film which is pattern adhered to a paperboard substrate in a fourth sealing pattern in accordance with the present invention;
[0019] FIG. 4B is a partially cut away front perspective view of a disposable insulated cup formed from the blank of FIG. 4A in accordance with the present invention.
[0020] FIG. 4C is a cross sectional view taken along line 4 C- 4 C of FIG. 4B ;
[0021] FIG. 4D is a partially cut away front perspective view of a disposable insulated cup formed from the blank of FIG. 4A in accordance with an alternative embodiment of the present invention;
[0022] FIG. 4E is a partially cut away front perspective view of a disposable insulated cup formed from a modified blank of FIG. 4A in accordance with another alternative embodiment of the present invention;
[0023] FIG. 4F is a partially cut away front perspective view of a disposable insulated cup formed from the modified blank of FIG. 4E in accordance with yet another alternative embodiment of the present invention;
[0024] FIG. 5 is side perspective view of a roller used in accordance with the present invention;
[0025] FIG. 6 is a schematic representation of a rotary heat sealing process in accordance with one embodiment of the present invention;
[0026] FIG. 7 is a schematic representation of an adhesive lamination process in accordance with another embodiment of he present invention; and
[0027] FIG. 8 is a schematic representation of an extrusion coating process in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Hereinafter, some preferred embodiments of the present invention will be described in detail with reference to the related drawings of FIGS. 1-8 . Additional embodiments, features and/or advantages of the invention will become apparent from the ensuing description or may be learned by the practice of the invention.
[0029] In the figures, the drawings are not to scale and reference numerals indicate the various features of the invention, like numerals referring to like features throughout both the drawings and the description.
[0030] The following description includes the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention.
[0031] In accordance with a preferred embodiment of the present invention and as generally shown in FIGS. 1A-1C , an elongated cup blank 14 ( FIG. 1A ) used to form a disposable thermally insulated cup 15 ( FIG. 1B ) is constructed from a paperboard substrate 20 having a strip of heat-activated shrink film 22 pattern-adhered to one side along a plurality of generally vertical seal lines 24 . Heat-activated shrink film suitable for practicing the present invention may be of the uniaxial or biaxial shrink film type which is available commercially from shrink film manufacturers such as DuPont® Corp. of Wilmington, Del. One example of a biaxial shrink film is DuPont® CLYSAR ABL® industrial shrink film. A uniaxial shrink film may be produced, for example, using an extrusion coating technique described hereinbelow in reference to FIG. 8 .
[0032] In general, biaxial shrink films are preferred for performance reasons. However, uniaxial shrink films provide satisfactory performance and are generally easier to apply in extrusion laminating and coating processes. The generally flat vertical sealing band pattern depicted in FIG. 1A extends between what will be an open cup top 16 ( FIG. 1B ) and a closed cup bottom 18 ( FIG. 1B ) of disposable thermally insulated cup 15 . In one example seal lines 24 may be spaced apart by about one inch with a seal line thickness of about one-sixteenth of an inch. Other seal line configurations may be utilized provided such other configurations do not depart from the intended purpose of the present invention.
[0033] Elongated cup blank 14 has (opposing) side edges 21 , 23 ( FIG. 1A ) which are sealed together along a generally elongated seam 19 ( FIGS. 1B-1C ) to form disposable cup 15 ( FIG. 1B ) with the pattern adhered shrink film 22 remaining on the interior side of the cup. The exterior side of cup 15 may have decorative graphics (not shown). The formed cup is then, preferably, run through an oven at sufficiently high temperature and for a period of time enough to cause heat-activated film 22 to sufficiently shrink, or pull away from paperboard substrate 20 (between seal lines 24 ) so as to form outwardly (away from the interior side of the cup) bulging and generally vertical air pockets 30 ( FIGS. 1B-1C ) which continuously run from bottom 18 to top 16 (of cup 15 ) over seam 19 and thermally insulate the entire exterior side of cup 15 from hot liquid contents such as hot coffee, tea or the like. Actual amount of shrinkage would also depend on film thickness. In general, care should he exercised to pick a gauge of heat-activated shrink film which would form pocket walls that do not easily puncture during normal use.
[0034] A person skilled in the art would readily recognize that thermally insulated disposable cup 15 of FIG. 1B may also be used to insulate a cup holder's hand from ice-cold contents, e.g. ice-cold soda, water, and the like.
[0035] In accordance with another preferred embodiment of the present invention and as generally shown in FIGS. 2A-2C , an elongated cup blank 34 ( FIG. 2A ) used to form a disposable thermally insulated cup 35 ( FIG. 2B ) is constructed from a paperboard substrate 39 having heat-activated shrink film 42 adhered to one side along a plurality of generally criss-crossing seal lines 44 . The sealing pattern depicted in FIG. 2A extends between what will be an open cup top 36 ( FIG. 2B ) and a closed cup bottom 38 ( FIG. 2B ) of disposable thermally insulated cup 35 . In one example, criss-crossing seat lines 44 may form generally flat one-inch square or diamond-like pattern ( FIG. 2A ) with a seal line thickness of about one-sixteenth of an inch.
[0036] Elongated cup blank 34 includes side edges 31 , 33 ( FIG. 2A ) which are sealed together along a generally elongated scam 37 ( FIGS. 2B-2C ) to form disposable cup 35 ( FIG. 2B ) with the pattern adhered shrink film 42 remaining on the interior side of the cup. The exterior side of cup 35 may have decorative graphics (not shown). The formed cup is then, preferably, run through an oven at sufficiently high temperature and for a period of time enough to cause heat-activated film 42 to sufficiently shrink, or pull away from paperboard substrate 39 (between seal lines 44 ) so as to form outwardly (away from the interior side of the cup) bulging air pockets 40 ( FIGS. 2B-2C ) which generally run from bottom 38 to top 36 (of cup 35 ) over seam 37 and thermally insulate the entire exterior side of cup 35 from hot liquid contents such as hot coffee, tea or the like. The newly formed thermally insulated disposable cup 35 may also be used to insulate a cup holder's hand from ice-cold contents.
[0037] In accordance with yet another preferred embodiment of the present invention and as generally shown in FIGS. 3A-3C , an elongated cup blank 49 ( FIG. 3A ) used to form a disposable thermally insulated cup 55 ( FIG. 3B ) is constructed from a paperboard substrate 59 having heat-activated shrink film 52 adhered to one side via a plurality of seal spots or dots 54 . The spot sealing pattern depicted in FIG. 3A extends between what will be an open cup top 56 ( FIG. 3B ) and a closed cup bottom 58 ( FIG. 3B ) of disposable thermally insulated cup 55 . In one example, seal spots 54 may form a generally flat ¾-inch square pattern ( FIG. 3A ).
[0038] Elongated cup blank 49 includes side edges 51 , 53 ( FIGS. 3A ) which are sealed together along a generally elongated seam 57 ( FIGS. 3B-3C ) to form disposable cup 55 ( FIG. 3B ) with the pattern adhered shrink film 52 remaining on the interior side of the cup. The exterior side of cup 55 may have decorative graphics (not shown). The formed cup is then, preferably, run through an oven at sufficiently high temperature and for a period of time enough to cause heat-activated film 52 to sufficiently shrink, or pull away from paperboard substrate 59 (between seal spots 54 ) so as to form outwardly (away from the interior side of the cup) bulging air pockets 60 ( FIGS. 3B-3C ) which generally run from bottom 58 to top 56 (of cup 55 ) over seam 57 and thermally insulate the entire exterior side of cup 55 from hot liquid contents. The newly formed thermally insulated disposable cup 55 may also be used to insulate a cup holder's hand from ice-cold contents.
[0039] In accordance with still another preferred embodiment of the present invention and as generally shown in FIGS. 4A-4C , an elongated cup blank 61 ( FIG. 4A ) used to form a disposable thermally insulated cup 65 ( FIG. 4B ) is constructed from a paperboard substrate 69 having heat-activated shrink film 62 adhered to one side along a plurality of generally horizontal seal lines 64 . The sealing pattern depicted in FIG. 4A extends between what will be an open cup top 66 ( FIG. 4B ) and a closed cup bottom 68 ( FIG. 4B ) of disposable thermally insulated cup 65 . In one example, generally horizontal seal lines 64 may be spaced apart by about one inch forming generally flat, elongated and parallel horizontal bands 63 ( FIG. 4A ) with a seal line thickness of about one-sixteenth of an inch.
[0040] Elongated cup blank 61 includes side edges 67 , 74 ( FIG. 4A ) which are sealed together along a generally elongated seam 70 ( FIGS. 4B-4C ) to form disposable cup 65 ( FIG. 4B ) with the pattern adhered shrink film 62 remaining on the interior side of the cup. The exterior side of cup 65 may have decorative graphics (not shown). The formed cup is then, preferably, run through an oven at sufficiently high temperature and for a period of time enough to cause heat-activated film 62 to sufficiently shrink, or pull away from paperboard substrate 69 (between seal lines 64 ) so as to form outwardly (away from the interior side of the cup) bulging and generally horizontal air pockets 72 ( FIGS. 4B-4C ) which run along the interior of the cup from bottom 68 to top 66 (of cup 65 ) over seam 70 and thermally insulate the entire exterior side of cup 65 from hot liquid contents such as hot coffee, tea or the like. The newly formed thermally insulated disposable cup 65 may also be used to insulate a cup holder's hand from ice-cold contents.
[0041] In accordance with an alternative embodiment of the present invention and as generally illustrated in FIG. 4D , an elongated cup blank (not shown) comprising a paperboard substrate 82 having heat-activated shrink film 84 adhered to one side along a plurality of generally horizontal seal lines 86 is used to form a disposable thermally insulated cup 80 ( FIG. 4D ). The horizontal sealing pattern depicted in FIG. 4D preferably extends between an open cup top 88 and a closed cup bottom 90 . In one example, generally horizontal seal lines 86 may be spaced apart by about one inch so as to form generally flat, elongated and parallel horizontal bands 92 .
[0042] The opposite side edges of the cup blank are sealed together along a generally elongated seam 94 ( FIG. 4D ) to form disposable cup 80 with the pattern adhered shrink film 84 remaining on the interior side of the cup. The exterior side of cup 80 may have decorative graphics (not shown). The formed cup is then, preferably, run through an oven at sufficiently high temperature and for a period of time enough to cause heat-activated film 84 to sufficiently shrink, or pull away from paperboard substrate 82 (between seal lines 86 ) so as to form outwardly (away from the interior side of the cup) bulging and generally horizontal thermally insulating air pockets 96 ( FIG. 4D ).
[0043] As generally depicted in FIG. 4D , thermally insulating air pockets 96 , preferably, run in the vertical direction along the interior of the cup from cup bottom 90 to cup top 88 . In the horizontal direction, thermally insulating air pockets 96 , preferably, run continuously along the interior of the cup on each side of elongated interior seam area 95 (which includes centrally seam 94 ), i.e. thermally insulating the entire exterior side of cup 80 except for the elongated exterior side area directly behind elongated interior seam area 95 (not shown). In this case, the disposable cup user should avoid touching the exterior side of disposable cup 80 in the area directly behind elongated interior seam area 95 as this area is not thermally insulated.
[0044] FIG. 4F shows a disposable cup 100 which is similar in construction to cup 80 of FIG. 4D except that cup 100 has been provided with a single generally horizontal thermally insulating air pocket 102 . Insulating air pocket 102 is preferably wider than its corresponding middle insulating air pocket 96 of FIG. 4D to provide greater insulation area and is adhered generally centrally to the interior surface of cup 100 on each side of an elongated interior seam area 106 (which includes centrally a seam 108 ). Horizontal air pocket 102 only provides thermal insulation coverage for the exterior surface of cup 100 located behind it with the exception of the elongated exterior side area located directly behind seam area 106 (not shown). Therefore, the disposable cup user should avoid touching the exterior surface of disposable cup 100 in any areas not covered by horizontal thermally insulating air pocket 102 as such areas are not thermally insulated.
[0045] FIG. 4E depicts a disposable cup I 10 which is similar in construction to disposable cup 100 of FIG. 4F except that cup 110 has been been provided with a single generally horizontal thermally insulating air pocket 112 which provides greater thermal insulation coverage. Specifically, insulating air pocket 112 is attached generally centrally to the interior surface of cup 110 over a seam 114 so as to provide continuous thermal insulation coverage over the corresponding exterior surface area of the cup (not shown). The disposable cup user should avoid, however, touching exterior surface areas (of disposable cup 110 ) located directly above and below the thermal insulation area provided by horizontal air pocket 112 as such areas are not thermally insulated.
[0046] In one test conducted by Applicant, a 75 gauge DuPont® CLYSAR LLG® polyethylene shrink film, which is similar to DuPont® CLYSAR ABL® industrial shrink film, and a paperboard stock of basis weight of about 143 lb/3000 sq. ft. and thickness of about 0.0128 inch were used as starting materials for forming the disposable thermally insulated cup of the present invention. Paperboard stock of this type may be purchased from Georgia-Pacific Corporation of Atlanta, Ga., which manufactures the stock at its Naheola mill. The CLYSAR LLG® shrink film was heat-sealed to the Naheola paperboard stock using an impulse heat sealer which can be a VERTROD CORP® MODEL 20A®, 1200-watt, heat sealer. A heat setting of “6” was used. The resulting disposable cup blank has a generally horizontal seal pattern, as shown in FIG. 4A . The straight side edges of the disposable cup blank were then brought together in an overlapping configuration and sealed on a bench fixture. The bench fixture holds the blank in a conical configuration while the seam area is heated and then clamps the seal, holding it in place until cooled. The seal areas were heated with a Wagner® model HT1000, 1200 watt, heat gun. The truncated cone (without top curl or bottom) was placed in a forced air oven at about 260° F. for about 10 seconds to force the film to shrink or pull away from the paperboard so as to produce the desired thermal insulating pockets. Five-second and thirty-second oven tests at the same temperature were also conducted. However, the five-second oven test resulted in insufficient film shrinkage, while the thirty-second oven test resulted in cone distortion due to excessive film shrinkage. Best results were achieved with an oven residence time of about 10 seconds. A silicone RTV sealant was used to seal the bottom of the cup in place. The cup bottom may also be heat-sealed into place. The cup bottom material used was paperboard stock of basis weight of about 120 lb/3000 sq. ft. and thickness of about 0.0113 inch. The paperboard was extrusion coated with about 20 lb/3000 sq. ft. of low density polyethylene (LDPE). Top curl was added later in the process.
[0047] The above-described novel disposable thermally insulated cup may be mass produced using several commercial sealing methods such as, for example, rotary heat sealing ( FIG. 6 ), adhesive lamination ( FIG. 7 ), and extrusion coating ( FIG. 8 ). All three methods employ a roller 120 comprising a solid generally cylindrical body 122 having a plurality of generally raised, cup blank-shaped regions 123 on its outer surface, and a shaft 124 , as generally illustrated in FIG. 5 . Raised, cup blank-shaped regions 123 are generally oriented in rows in a back/forth pattern to minimize material usage. The resultant pattern requires that so-called scroll (zig-zag) slitting be used later in the manufacturing process. The cup blank-shaped regions may come in a single pattern or in a variety of patterns and are raised for printing, heat sealing, or for applying pressure during extrusion coating. Specifically, the raised patterns on cylindrical body 122 are used to form the various seal lines, seal spots described hereinabove.
[0048] As generally depicted in FIG. 6 , a moving shrink film 126 and a moving paperboard stock 128 are brought together in the nip formed by heated roller 120 and a pressure roller 130 . Heated roller 120 and pressure roller 130 heat-seal shrink film 126 onto paperboard stock 128 in the various patterns of FIGS. 1A, 2A , 3 A, 4 A producing a web of heat-sealed patterns 132 from which elongated cup blanks will be cut ( FIG. 6 ).
[0049] The adhesive lamination technique generally shown in FIG. 7 uses roller 120 essentially as a flexographic printing or application roller to apply adhesive 134 to shrink film 136 which rides around a roller 138 . Adhesive 134 , which is contained in a pan 133 , is applied to application roller 120 via a conventional anilox roller 121 which is in rotational contact with application roller 120 . Anilox roller 121 , which is dipped to a certain extent in adhesive pan 133 , picks up adhesive 134 for transfer to application roller 120 . A blade 135 is also provided, as generally shown in FIG. 7 , to automatically scrape away excess adhesive from anilox roller 121 during operation. The shrink film with the applied adhesive is then laminated to a moving paperboard stock 140 in the nip formed by film roller 138 and a pressure roller 142 in the various patterns of FIGS. 1A, 2A , 3 A, 4 A producing a web of adhesively sealed patterns 144 from which elongated cup blanks will be cut ( FIG. 7 ).
[0050] The extrusion coating technique of FIG. 8 uses roller 120 as an impression roller. Specifically, an extrusion die 146 applies a continuous stream of polymer melt 148 to a moving paperboard stock 150 in the nip formed by impression roller 120 and a chill roll 152 ( FIG. 8 ). Chill roll 152 turns polymer 148 from liquid form to a film at the same time as the polymer is being adhered to moving paperboard stock 150 by impression roller 120 in the various patterns of FIGS. 1A, 2A , 3 A, 4 A producing a pattern-adhered web 154 from which elongated cup blanks will be cut ( FIG. 8 ).
[0051] Alternatively, a heated mandrel having at least one undercut section and raised ridges (not shown) may be used to heat-seal shrink film onto the paperboard stock. The resulting cup blank may include, for example, a single centrally located insulating band which can be used to form disposable thermally insulated cup 100 of FIG. 4F . In this regard, a mandrel heated to about 240° F. was used by Applicant to produce a prototype disposable thermally insulated cup of the type shown in FIG. 4F .
[0052] In general, the following manufacturing steps may be used to produce the novel disposable thermally insulated cup. Step 1 involves printing or decorating one side of the paperboard stock, this side will be used to form exterior cup sides. Step 2 deals with pattern-adhering of the shrink film onto the opposite side of the paperboard stock to produce a pattern-sealed web using one of the above-described techniques, i.e. extrusion coating, rotary heat sealing, or adhesive lamination. This side will be used to form the interior cup sides. The end result is a roll of paperboard stock with pattern-adhered film which is then taken to a slitter. The slitter cuts the paperboard stock/pattern-adhered film roll into narrower rolls corresponding to the width needed to cut a series of cup blanks (Step 3 ). The slit rolls are then placed one at a time on a cup-making machine which forms the entire cup, i.e. cuts the cup blanks from the rolls, seals the side seams, attaches cup bottoms, and applies top curls (Step 4 ). Step 5 includes placing the formed cups in an oven at sufficiently high temperature and for a period of time enough to cause the pattern-adhered film to sufficiently shrink, or pull away from the paperboard stock so as to form the thermally insulating air pockets described hereinabove and shown, for example in FIGS. 1B, 2B , 3 B, 4 B, and 4 D- 4 F. After that the thermally insulated disposable cups are taken out of the oven and cooled at ambient (room) temperature (Step 6 ). The cooled thermally insulated disposable cups are then shipped to customers or stored by the manufacturer for future shipment (step 7 ).
[0053] In accordance with another preferred embodiment of the present invention, above-described steps 5 - 6 may be avoided entirely if the film used in above-described pattern-adhering step 2 is capable of automatically shrinking or pulling away from the interior paperboard wall of the cup at a temperature range of about 180°-190° F. so as to form thermally insulating air pockets, i.e. after the pouring of a hot liquid such as hot coffee, tea, or the like. Hot coffee temperature, for example, is generally in the same range, ice. 180°-190° F. In this regard, the following two experiments were performed by Applicant to prove that hot liquids can be used to effect shrinking of such heat-shrinkable films on the interior of disposable cups.
[0054] A DuPont® Clysar ABL® 200 shrink film was sealed with a Vertrod® impulse heat sealer to the top and bottom of a cup blank which was polyethylene (PE) coated on both sides. The cup blank was then heat-sealed into a truncated cone into which a bottom was sealed with RTV (room temperature vulcanizing) silicone. The truncated cone was not top curled. Thereafter, water at about 190° F. was poured into the conical shell. It was subsequently found that the film had shrunk only if it contained a pinhole or if it had been intentionally pre-slit. In the areas where there was no break in the film, partial vacuum had developed which prevented the film from sinking or pulling away from the interior wall of the conical shell. The pre-applied PE coating on the two sides of the cup blank prevented air intrusion between the shrink film and the interior (PE-coated) wall of the conical shell. To alleviate the partial vacuum problem, a series of pinholes were punched through the cup blank (to allow air intrusion) prior to heat-sealing the shrink film to the paperboard stock and the experiment was repeated. This time the pattern-adhered film shrunk sufficiently (after the pouring of hot water) to automatically form the desired thermally insulating air pockets.
[0055] A person skilled in the art would recognize that other types of shrink films capable of performing at other hot liquid temperature ranges may be utilized to achieve the above results provided such other types of shrink film do not depart from the intended purpose of the present invention. A person skilled in the art would also recognize that the above results may be achieved using uncoated paperboard stock or paperboard stock that is coated only on one side with PE. Other configurations and/or modifications may be used, providing no departure from the scope and spirit of the invention occurs.
[0056] A disposable cup with a pattern-adhered insulating shrink film interior capable of automatically shrinking, or pulling away from the interior wall of the cup after pouring a hot liquid so as to form thermally insulating air pockets would only be suitable for insulating a cup holder's hand from hot contents. Pouring of cold liquids in such a cup would not trigger any film shrinkage and should, therefore, be avoided. In general, the manufacture of such disposable cups, i.e. cups that are capable of automatic heat-insulation, should be preferred from a manufacturer's point of view due to reduced cost of manufacture (above-described steps 5 - 6 being omitted) which would translate into a reduced overall cost, and reduced overall volume of nested or stacked cups which can be advantageous for storage and/or shipping purposes.
[0057] A person skilled in the art should recognize that the above-described novel disposable cup provides improved thermal insulation capability over known disposable insulated cups. The novel disposable cup also exhibits no tendency to soften (i.e., deform) under hot liquid contents as, for example. conventional foam cups tend to do. Moreover, the novel disposable cup may be manufactured with higher quality graphics (decoration) on its exterior side compared to known disposable cups which tend to have a so-called “blistered” outer surface which distorts somewhat the applied graphics. The above-described novel disposable thermally insulated cup manufacturing process may be employed in any field or application where effective thermal insulation capability is required. An alternative application may include cushioning capability for packaging, and the like.
[0058] While the present invention has been described in detail with regards to the preferred embodiments, it should also be appreciated that various modifications and variations may be made without departing from the scope or spirit of the invention. It is important to note that practicing the invention is not limited to the applications described hereinabove. Many other applications and/or alterations may be utilized provided that such other applications and/or alterations do not depart from the intended purpose of the present invention.
[0059] It should further be appreciated by a person skilled in the art that features illustrated or described as part of one embodiment can be used in another embodiment to provide yet another embodiment such that the features are not limited to the specific embodiments described above. Thus, it is intended that the present invention cover all such modifications, embodiments and variations as long as such modifications, embodiments and variations come within the scope of the appended claims and their equivalents.
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A container blank comprises at least one substrate layer made of disposable material and at least one film layer disposed substantially over the substrate layer and having at least one portion adapted to shrink away from the substrate layer upon application of heat. The shrunk film layer portion is adapted to thermally insulate the substrate layer located substantially behind the shrunk film layer portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. national phase of the International Patent Application No. PCT/FR2010/051092 filed Jun. 3, 2010, which claims the benefit of French Application No. 09 53846 filed Jun. 10, 2009, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to automated assistance for visually-challenged persons (blind or with poor vision) for aiming at archery or rifle targets in the context of sport competitions.
BACKGROUND
A prior art aiming assistance system offered by the German company Swarovsky is represented in FIG. 1 . It comprises a circular grayscale target pattern MI (the grayscales darkening from white to black from the center of the target to the edge), placed just above the target CI. The target pattern is brightly lit by a light placed just above it, and at the focal point of the scope LU mounted on the weapon AR there is a light intensity sensor (typically a monopixel detector). When the center of the target pattern MI is imaged on this detector, the light intensity is at its maximum, and an acoustic signal is sent to the shooter to indicate that his weapon is aiming at the center of the target CI. One will note that the scope LU is pre-oriented to the angle a formed by the axis passing through the scope LU and the target pattern MI, relative to the aiming axis (from the weapon AR to the center of the target CI).
Adjusting the position of the target pattern MI relative to the target must be done with precision, so that the same value of the angle a is defined and the shooter always has his weapon facing the center of the target. In addition, the position of the target pattern MI relative to the target CI must be adjusted each time to the position of the shooter (according to his distance to the target (200, 100, or 50 meters), whether he is standing, crouched, or lying down, etc.).
Such a system is therefore fairly difficult to use and is impractical for competitions.
In addition, a “tilt” problem occurs if the shooter does not maintain the same exact position when shooting. This type of system communicates to the shooter an aiming direction which is offset from what the system is truly trying to detect (the target pattern MI in this case), and due to the initial alignment of the weapon to a point which is not the center of the target CI, it has been observed than a tilt angle a disrupts the quality of the shot.
Targets for competitive shooting generally have officially defined characteristics and therefore do not vary in shape and/or color, whether they are intended for use by persons with or without disabilities. There is no question of changing the appearance of the targets to adapt them to existing aiming-assistance systems.
SUMMARY
The present invention improves the situation.
It first proposes a method, implemented by computerized means, to assist a visually challenged or blind person with aiming at a shooting target, comprising:
providing the shooting weapon to be used by the person with a camera placed on the weapon to capture images of the target to be aimed at, identifying the target by shape recognition in the images captured by the camera, emitting a signal to be perceived by the person to guide the person in orienting the shooting weapon towards the target.
By seeking to recognize the target itself, using shape recognition in advantageous embodiments which will be described below, it is no longer necessary to install an additional target pattern and no tilt angle interferes with the quality of the shot. The characteristics of the target itself are used to recognize and locate its center.
In an advantageous embodiment, after the target is identified in the captured images, the center of the target is determined and the emitting of the signal guides the person in orienting the weapon, particularly towards the center of the target.
This advantageous embodiment is based on the fact that the target displays a circle, disk, or ring (at least one), as do most shooting targets as will be discussed below with reference to FIGS. 4A and 4B . In an advantageous embodiment, the shape recognition in the sense of the invention comprises a Hough transformation to identify such a shape in the captured images, and from that, the center of this circular shape.
More specifically, if the target has a plurality of shapes forming at least one concentric circle, ring, or disk, the Hough transformation allows identifying, among this plurality of circular shapes, at least two shapes having respective centers that are separated by a distance of less than a chosen tolerance threshold. If these two shapes can be identified, it can be decided that the center of the target is the barycenter of the centers of the two circular shapes.
Advantageously, there is a confirmation of the identification of the target obtained by the shape recognition as described above.
In one embodiment, the color of the target is made use of to confirm the shape recognition. For example, one can use recognition of a color contrast between different rings of a particular color, such as the rings of an archery target. Additionally or alternatively, two shape recognitions can be carried out:
a first shape recognition in grayscale images, and a second shape recognition, using color, performed on color images and using a selected color component (green for example in a RGB (Red Green Blue) image).
The second shape recognition confirms the result of the first grayscale shape recognition, but in the color image.
As an alternative or addition to the types of shape recognition described above, because a rectangular board is generally used to support the shooting target, the shape recognition of the invention can comprise the identification of four corners having angles close to 90° and spaced apart by predetermined relative distances (for example by the same relative distance if it is a square, as will be further described below).
One particular embodiment can consist of:
applying a first shape recognition comprising a Hough transformation, and confirming the obtained results by a second shape recognition based on the identification of four corners.
In a practical embodiment of the invention, a processing module can be connected to the camera, by means of which:
selected shape characteristics of a target model are stored in memory, data for the current image are received from the camera, the current image data are examined for shape characteristics which are homologous to the model characteristics (for example a given number of concentric circles, four corners with predetermined distance ratios between corners, or other characteristics), and if characteristics identical to the model characteristics are identified in the current image data, within a certain tolerance (this tolerance for example taking into account perspective effects, differences in color temperature from the lighting, distance between camera and target, or other effects):
the recognition of the target in the current image is validated, a distance is determined between the target and a center of aim of the camera, and an output signal is issued for which at least one parameter is a function of this distance.
In practice, a signal is delivered which is a function of:
the distance in height (angle of elevation to be corrected for the shooter), and the horizontal distance to the target (angle of azimuth to be corrected for the shooter).
One can then choose an acoustic output signal and modulate this signal with at least one parameter from among an amplitude, an amplitude of spatialization (between the right earpiece and the left earpiece of a headset, for example), a fundamental frequency, and a modulation frequency (in the form for example of beeps that are closer together or further apart), as a function of the above distance.
The invention also relates to a system to assist with aiming at a shooting target, which applies the above method and comprises:
a camera to be placed on a weapon to be used by the person, to capture images of a target, a device connected to the camera, for identifying the target by shape recognition in the images captured by the camera, and a means, for example a stereophonic headset or an earpiece, connected to the device, for emitting a signal to be perceived by the person to guide the person in orienting the shooting weapon towards the target.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be apparent from reading the following detailed description and the attached drawings in which, aside from the previously described FIG. 1 which concerns the prior art:
FIG. 2 schematically illustrates a system of the invention, assembled on a weapon,
FIG. 3 illustrates the general steps of a method of the aiming assistance invention,
FIGS. 4A and 4B are target images captured with a camera in two distinct focal length configurations, and
FIG. 5 schematically represents a device according to the invention for processing image data provided by the camera, determining the presence or absence of the target in the images provided, and in particular identifying the center of the target if applicable.
DETAILED DESCRIPTION
As illustrated in FIG. 2 , an aiming assistance system of the invention comprises a camera CAM capturing images of the target CI in order to identify the target by shape recognition when the weapon (bow, rifle, dart, or other weapon) is pointed towards the target. When the complete shape of the target is recognized by the camera using a zoom adjusted to the assumed distance of the target, an audible signal sounds in the earpieces OR worn by the person to be assisted, to indicate to him that the weapon AR is pointed towards the target.
In an exemplary embodiment, the camera CAM can send a video signal by a wired or wireless link (Wifi or other) to a device DIS that the shooter can wear (for example in a backpack or by other means). The advantage of such an implementation is that it limits the weight mounted onto the weapon to the weight of the camera only, because the heavier the weapon the greater the inaccuracy of the shooter due to muscle fatigue.
A processor PROC equipped with working memory receives video data, defines an image, and compares the shape of this image with a presaved model (or more specifically as will be seen below, compares certain characteristics of this image to those of the model). In an exemplary embodiment described in detail below, the shape recognition is based on a Hough transformation. This type of processing is well suited for the recognition of circular shapes. Circle recognition by Hough transformation generally consists of the following steps
identifying substantially uniform contrasting areas in an image (for example an area where the grayscale is constant within a certain tolerance), defining tangents to this area, determining the normals to the tangents, and verifying that they are (almost) all secant (within a certain tolerance) at a point which is the center of a circle or disk formed by the area.
This circle detection, as well as a square detection for identifying the physical edges of the target, will be detailed below.
The earpieces OR can be in the form of a headset with small speakers for the right and left ears. The angle of elevation for the aim can be adjusted by varying the tone relative to a reference frequency. Thus the speakers can reproduce:
a first signal varying in frequencies and depending on the height of the aiming axis relative to the target, and a reference second signal of constant frequency.
This second signal can be reproduced at a sound level that is equal between the two speakers, so that the shooter has the sensation that this reference signal is centered between his two ears. The first signal can be reproduced at a sound level which varies between the two speakers as a function of the angle of azimuth of the aiming axis relative to the target. When the shooter has the impression of hearing the two signals completely “superimposed” as he moves his weapon, the aiming axis passes through the center of the target and the user can shoot.
As a variant, to assist with adjusting the angle of azimuth, the first signal can consist of emitting beeps at a frequency which increases as the aiming axis approaches the target horizontally, until a continuous signal is heard, in which case the user can fire. One will note that a stereophonic headset is not necessary in this variant and a single earpiece is sufficient.
In a less sophisticated variant which still provides good results, the first signal consists of emitting beeps at a frequency which increases as the aiming axis approaches the target for the angles of azimuth and elevation indistinguishably, until a continuous signal is reached, in which case the user can fire. In this embodiment, reproducing a reference signal is unnecessary and a single earpiece is sufficient.
However, a difficulty arises in implementing the invention, particularly in outdoor or hazy conditions: increasing the tolerance for the target detection in such conditions (with variations in the natural lighting on the target, possibly with slight haze or mist, etc.) allows better detection of the target but leads to a risk of false positives in the detection, which is of course hazardous in a context of weapon use.
An advantageous embodiment proposes combining the shape recognition described above with recognition based on the color of certain target elements and/or on square recognition, as described below.
In archery, the targets have an outside diameter of 122 cm and consist of concentric circles of colors in the sequence, from the outside to the inside, of white, black, blue, red, and yellow, on a white background.
In riflery, the targets have an outside diameter of 155 mm and consist of ten concentric circles on a white background with a central mark (three black concentric disks) 59.5 mm in diameter, on cardboard that is 170 mm per side.
In both cases, the target and its center are detected by processing images as illustrated in FIG. 3 . The processing first consists of grayscale circle detection (step S 31 ) in a current image IM. The circles correspond:
for archery, to the various concentric circles on the target of different colors, and for riflery, to the black central mark.
The circle detection is advantageously based on using the Hough transform, which corresponds to determining the intersection of lines perpendicular to the contours as explained above. The points of the image having a large number of line intersections are the centers of the circles. The Hough transform is classic and can be found in the libraries of traditional computerized tools.
In particular, grayscale circle detection comprises the following operations, in an exemplary embodiment:
converting the color image into grayscale, applying a Gaussian filter (for example 9 pixels by 9) to reduce noise and decrease false detections, and applying the Hough transform while retaining only the first circle detected (typically the circle having the center with the largest number of intersections).
The processing can additionally comprise, for example, square detection, particularly the outside edges of the target board. This detection (step S 32 ) is based on the use of specific processing defined as follows:
detecting boundaries in the image, selecting boundaries using the following criteria:
there are four and only four sides to be identified, the boundary line is closed, the angle formed by two consecutive sides must be 90° (within a certain tolerance due to a slight possible perspective effect, depending on the position of the shooter), the area within the boundary must be between two thresholds (min and max), the ratio between the largest side and the smallest side must be close to one, within a certain tolerance.
In the example represented in FIG. 3 , several criteria are used to detect a shooting target:
detection of a circle in a grayscale image (step S 31 ), detection of squares (step S 32 ), and detection of a circle in an image corresponding to a component in the color space (step S 33 ).
When selecting the color used for the third detection, detecting the “Green” component of the RGB (Red Green Blue) color space has been found to be the most relevant in competition conditions. The main steps of this detection are as follows:
selecting the Green component (for example green pixels within a certain tolerance) in the color image, applying a Gaussian filter (for example 9×3) to reduce noise and decrease false detections, and applying the Hough transform with only the first detected circle retained (circle having the center with the largest number of intersections).
One can see that the circle detection is repeated independently of the grayscale circle processing done in the previous step S 31 .
Thus for a current image IM:
circle detection is performed in the grayscale image (S 31 ), for the same image, square detection is performed (S 32 ), for the same image, circle detection is performed in the color image (S 33 ).
Then the coordinates (x,y for a two-dimensional image) are determined:
for the center of a first circle obtained in step S 31 , for the center of a square obtained in step S 32 , and for the center of a second circle obtained in step S 33 .
These coordinates are considered to be validated if the distance between the centers, taken two by two, is always less than a given threshold (near 0). Otherwise the detections are rejected (the arrow N from the test T 36 in FIG. 3 ) and the detections are repeated on a new current image. No acoustic signal is emitted for the shooter as long as the coordinates of the detected centers have not been validated.
If the detections are positive, the barycenter of the validated centers is considered to be the center of the target in step S 34 . By comparing the position of this barycenter with that of the central area of the image (for example the 9×9 pixels in the center of the image):
the difference in pixels along the vertical axis y is calculated and a corresponding acoustic signal is emitted for the shooter (for example at a frequency dependent on this difference taken as a positive or negative value), to indicate a deviation in the angle of elevation φ component of the aim, and the difference in pixels along the horizontal axis x is calculated and a corresponding acoustic signal is emitted for the shooter (for example with a difference in intensity in the speakers of his stereophonic headset which is dependent on this difference taken as a positive or negative value), to indicate a deviation in the angle of azimuth θ component of the aim.
Combining two of the three detections presented above has been found to be sufficient to ensure that the target has been properly located, without false positives.
However, tests have found that the combined detection of grayscale circles and squares did reduce false positives but had the result of increasing the processing time, which adversely impacts shooting accuracy because the shooter is moving during this processing time.
Using the two circle detections S 31 and S 33 (one using a grayscale image, and the other using the same image in color), both based on a Hough transformation, yields good results for both the reliability of the detection and the processing in real time, with the sound heard by the shooter perceived as being instantaneous in response to his movements.
Another parameter to be optimized is the adjustment of the focal length (zoom) of the camera relative to the distance between the shooter and the target. To ensure accurate detection of the center of the target in the image, the dimensions of the target in the current image preferably must be as large as possible without falling outside the edges of the image. The corners of the target should then more or less coincide with the edges of the image (as represented in the view in FIG. 4B of an official archery target). However, for the sound indicators to be effective for the shooter, the image must encompass the target as well as its surroundings. In other words, for the camera to be able to capture the target in its field with the shooter then alerted to limit the amplitude of his movements, the image captured by the camera must typically have a width of three to five seven times that of the target (as represented in the view in FIG. 4A of an official target for pistol shooting at 10 meters).
Of course, depending on the means available and particularly the pixel resolution of the camera, a more or less powerful zoom can be chosen (less zoom when the camera resolution is high).
To use a weapon equipped with the same camera, of a given resolution, in several types of competition, it is therefore advantageous to preadjust the zoom of the camera according to:
the target size, and the target distance
for each type of competition.
Of course, the invention is not limited to the embodiment described above as an example; it extends to other variants.
For example, it is understood that the choice of the color green for the shape recognition confirmation conducted in the color image can vary with the implementation conditions and particularly the lighting conditions on the target (in a shooting gallery or outdoors for example).
The use of color in the obtained images can imply shape recognition in a given color (green for example), but also a recognition of color contrasts in the target. This embodiment is particularly applicable in the case of an archery target, where it is possible to rely on recognition of the colors of the different concentric rings to confirm the grayscale shape recognition ( FIG. 4B ).
With reference to FIG. 5 , the invention also relates to a device DIS of a system to assist a visually challenged or blind person with aiming at a shooting target, comprising:
a memory MEM for storing the selected shape characteristics of a target model, an input E 1 for receiving current image data from the camera CAM, and a processor PROC for:
searching the current image data for shape characteristics that are homologous to the model characteristics, and if characteristics identical to the model characteristics are identified in the current image data, within a certain tolerance:
deciding that the target has been recognized in the current image, determining a distance between the target and a center of aim of the camera,
and an output S 1 for delivering a signal for which at least one parameter is a function of this distance.
The invention also relates to a computer program to be stored in the memory of such a device and comprising instructions for carrying out the method of the invention, when they are executed by the processor PROC of the device. As an example, FIG. 3 can represent a flow chart for such a computer program.
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An automated aiming assistance towards a shooting target for a visually- challenged or blind person is provided. The method comprises: providing the shooting weapon used by the person with a camera placed on the weapon for filming the target to be aimed at; identifying the target by shape recognition in the images shot by the camera; and transmitting a signal received by the person for guiding the person for orienting the shooting weapon towards the target.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit to U.S. Provisional Application No. 61/316,348 filed on Mar. 22, 2010, the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to gun-fired and mortar rounds, and more particularly, to remotely guided gun-fired and mortar rounds.
2. Prior Art
Gun-fired munitions and mortars with certain amount of guidance and control capabilities have been developed. Such munitions use either GPS signal alone or in combination with inertial sensors to arrive at a preprogrammed target position or use radar to close a target intercept guidance and control loop. Such munitions have numerous shortcomings including incapability of having a decision making person in the loop, generally incapable of intercepting moving targets without complex sensory systems, as well as being complex systems to produce and operate and are very costly.
Therefore there is a need for a method of guiding gun-fired and mortar round that incorporate a simple design, that can have a person in the decision loop, is low cost, particularly for mortars for close combat operations that would minimize collateral damage and minimize unexploded ordinances (UXO), and can also relay back information about target intercept or the lack thereof and its intercept position.
SUMMARY OF THE INVENTION
Accordingly, a system for guiding a gun-fired or mortared round towards an intended target is provided. The system comprising: a round having: a forward facing image pick-up device for capturing image data; a first transceiver; guidance means for varying a flight path of the round; and a first processor; and a control platform remotely located from the round, the control platform comprising: a second transceiver; a second processor; an input means; and a display; wherein the first processor transmits image data from the image pick-up device through the first transceiver to the second processor through the second transceiver, the second processor transmits guidance information from the second transceiver to the first processor through the first transceiver and the first processor controls the guidance means based on the guidance information to guide the round towards the intended target.
The one or more of the image data and guidance information can be directly or indirectly received at the second and first transceivers, respectively.
The image pick-up device can be one of a black and white camera, color camera, infra-red camera or multi-pixel camera.
The input means can be one of a keyboard or joystick.
The round can further comprise a means for slowing the descent of the round. The means for slowing the descent of the round can be a parachute. The means for slowing the descent of the round can be variable.
The guidance means can includes one or more of a controllable fin or controllable canard disposed on the round. Each of the fin or canard can be associated with an actuation means for moving the associated fin or canard. The actuation means can be one of an electrical motor or actuation device.
The guidance means can include one or more thrusters positioned on the round.
One of the first or second processor can include image processing for at least reducing a rotation or translation of the image data on the display.
The system can further comprise means for at least reducing a spin or translation of the round during descent.
The operator can generate the guidance information by manually directing the round towards the intended target based on the image data displayed on the display.
The guidance information can be generated by the second processor through automated recognition of the intended target in the image data.
The guidance information can be generated by the operator marking the intended target on the display with the input means and the second processor calculating the guidance information based on the mark.
The operator can generate an arm signal with the input means which is transmitted from the second processor through the second transceiver to the first processor through the first transceiver, the first processor arming a warhead in the round.
The operator can generate a disarm signal with the input means which is transmitted from the second processor through the second transceiver to the first processor through the first transceiver, the first processor disarming a warhead in the round.
The round can further comprise a GPS receiver operatively connected to the first processor.
The first processor can transmit position data through the first transceiver to the second processor through the second transceiver.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 illustrates a schematic of a system for remotely guiding a round to an intended target.
FIG. 2 illustrates a schematic of a round used in the system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention discloses a remotely guided round 100 that may be fired from a gun 102 or a mortar. Once the round 100 is launched, during its initial portion of its flight, such as at its apogee 104 , the round is intended to follow its ballistic trajectory, even though the round 100 may also be equipped with post-firing means of propulsion.
Referring to FIGS. 1 and 2 , the round is provided with at least one substantially forward facing camera 106 (preferably viewing through a transparent portion 107 of the casing 108 ), which during the descent is directed substantially towards the intended target 110 , captures images of the general target area and wirelessly transmits such images to a weapon control platform 112 remotely located from the round 100 . The camera 106 can be mounted at or near the nose area 108 a of the round. The image(s) is/are transmitted from the onboard camera 106 to the weapon control platform 112 via a secure two-way radio link by any means known in the art, such as by RF signal. The signal can be directly detected at a transceiver 114 at the remote weapon control platform 112 or through an intermediate receiver/transmitter, such as a satellite or nearby UAV(s).
The onboard camera 106 can be black and white to reduce the amount of data that needs to be transmitted, thereby increasing the rate at which the image can be refreshed. In certain applications, however, full or partial color may be preferable. In another embodiment, infra-red sensitive cameras can be used to enable night imaging capability. Alternatively, cameras sensitive to both infra-red and daylight (e.g., multi-pixel type) could be used.
At the weapon platform 112 , the image(s) transmitted by the transceiver 120 on board the round 100 are received by the transceiver 114 at the weapon platform 112 and can be displayed on a monitor 116 for the operator to view. The monitor 116 can be mounted on a “fire control” console used by the operator for weapon guidance and control purposes, the mode of operation of which is described below.
Following launch and at some point in its trajectory, such as up to apogee 104 , the round 100 is intended to follow its ballistic trajectory. The round 100 is provided with large enough fins (fixed or deployable) 100 a so that during its descent (flight past the apogee), its nose 108 a is pointing downwards towards the earth/target. The round 100 may be provided with a means to slow down its rate of descent. One such means is a parachute 118 that can be deployed once the round has passed apogee 104 . Other means for slowing descent include a “propeller” shaped element that is positioned at or near the tail of the round. In one embodiment, the “propeller” is attached to the housing of the round near the tail (fins) via bearings that allow it to rotate about the long axis of the round. Alternatively, the “propeller” is fixed to the housing of the round. In another embodiment, the “propeller” also serves as the round fin, since the drag that it produces serves the same function as the fins to stabilize the round during its flight. In yet another embodiment, two such rotating propellers can be used as previously described, such as being mounted on bearings on the same shaft, but are designed to rotate in the opposite direction as the round descends. By having two identical propellers (in size and the air displacement/drag producing characteristics) but rotating in opposite directions, the net torque acting on the round about its long axis which would tend to cause the round to spin is thereby minimized. Other means for slowing the descent include deployable surfaces which increase the drag of the round
Furthermore, the rate of descent can be variable, such as by simply jettisoning the parachute 118 or a portion thereof. Where the operator has the round directed to the target, the operator may choose to jettison the parachute 118 to increase the rate of descent. Means for jettisoning parachutes and the like are well known in the art, such as with explosive fasteners 126 .
During the descent, if the round 100 has been fired in the general direction of the target 110 and if the target 100 is in the field of view of the camera 106 , the weapon system operator can view the target 106 on the fire control system monitor 116 .
The round 100 can also be provided with means to actively control its trajectory, preferably by providing flight control surfaces such as controllable fins 100 a or canards 100 b . The control surfaces can be actuated by onboard control microprocessor and related electronics (collectively referred to as an on-board microprocessor and by reference numeral 121 ) using electrical motors or actuation devices (generally referred to by reference numeral 123 ) that consume very low electrical energy such as those disclosed in U.S. patent application Ser. Nos. 12/217,605 (U.S. Publication No. 2010/0275805) and 12/217,604 (U.S. Publication No. 2010/0275595) filed on Jul. 7, 2008, the contents of each of which are incorporated herein by reference.
In an embodiment, the guidance and control system of the disclosed weapon system operates as follows. During the descent, the operator observes the intended target 110 on the fire control system monitor 116 . In this control system, the camera 106 acts as the sensor that displays the position of the target 110 relative to the round 100 in the field of view of the camera 106 . The control system console 112 is also provided with an input means 122 , such as a keyboard or joystick that by, e.g., moving it to the right and left or up and down, a signal is transmitted to the round's onboard microprocessor 121 to actuate the control surfaces ( 100 a , 100 b ) to guide (divert) the round 100 to the right or left and/or up or down as referenced in the view observed in the fire control system monitor 116 . This process will then continue until the target 110 is intercepted. In such a system, the operator may also provide a signal to arm the round 100 , e.g., by pressing a button on the joystick, keyboard or the like. By providing such a feature, the operator has the option of not arming the round 100 if it is determined that there is no target of interest in the field of view of the weapon or if the weapon has been fired towards an unintended site or for any other relevant reason. Alternatively, the round 100 may be armed (upon firing or during the flight and a relatively significant distance from the target), and the operator can have the option of disarming the round 100 if it is determined that there is no target of interest in the field of view of the weapon or if the weapon has been fired towards an unintended site or for any other relevant reason. The operator can also arm the round at certain time and disarm it at a later time, e.g., prior to impact with the target 110 . The weapon control platform 112 includes a controller/processor and associated electronics (collectively referred to as a controller and by reference numeral 113 ) for controlling/coordinating the operation of its constituent features (e.g., monitor 116 , transceiver 114 and input means 122 ).
In such a system, the onboard camera 106 together with the weapon system operator acts as an inexpensive “homing sensor” for the round guidance and control system.
It is noted that the use of control surfaces such as fins and canards for guidance is well known in the art and are commonly used in gun-fired projectiles and missiles. In addition or in place of such control surfaces, thrusters may be used to guide the round, such as the chemical thrusters 125 disclosed in U.S. Pat. No. 7,800,031 and U.S. patent application Ser. No. 12/877,075 filed Sep. 7, 2009, the contents of each of which are incorporated herein by reference.
The round can have a minimal rate of spin during the descent so that it is easier for the weapon system operator to correct the trajectory of the round to intercept the target. The weapon control platform 112 can be provided with an image processing algorithm that would allow the image viewed on the monitor 116 to be substantially still rotationally and/or in translation to make it easier for the operator to perform guidance and other control and operational tasks. This would also allow the rate of descent to be selected to be higher, thereby increasing the element of surprise and minimizing the amount of time that the target would have to avoid being intercepted. Image processing algorithm for correcting for spin and translation are well known in the art. Alternatively, control surfaces or thrusters can be used to reduce or even eliminate the spin.
In yet another embodiment, the image received at the fire control system may be used to automatically detect the target using image processing and pattern recognition algorithm by the weapon control platform's controller 113 , which could directly send the required guidance and control signals to the round microprocessor 121 until the target is intercepted. Such a process may include intervention of an operator, e.g., to give the go-ahead to the target interception, arm or disarm the warhead or to verify the target or the like.
Alternatively, the operator can mark the target on the display 116 and the controller 113 can automatically guide the round to the target by sending the required guidance and control signals to the round microprocessor 121 until the target is intercepted. As such, the operator can use a pointing device, such as a trackball, mouse, joystick and the like to position a pointer over the intended target and indicate the target by clicking, pushing a button or the like. The controller 113 then automatically guides the round to the target and sends the required guidance and control signals to the round microprocessor 121 until the target is intercepted.
In yet another embodiment, the round can be released from an airborne vehicle such as an UAV or manned airplane or a missile. The round may also be a sub-munition that is released from a cargo round carrying multiple such sub-munitions.
It is appreciated by those familiar with the art that such a round may also be equipped with numerous other sensory devices and seekers to provide more capabilities to the user, such as detection at a distance to the target, which can also be displayed to the operator on the monitor 116 . However, in general, each addition of such sensory devices and/or seekers increases the system complexity, requires more electrical power to operate and thereby require larger onboard power sources, and in effect reduce the volume available for weapon lethality.
In yet another embodiment, the round 100 can be provided with a GPS sensor 124 that is used for navigation, guidance and/or control purposes, in addition to the aforementioned camera based guidance and control and in certain situations in place of the aforementioned camera based guidance and control system.
The aforementioned GPS sensor can be used by the round to constantly determine its position relative to the earth and transmit that position back to the fire control system at the weapon control platform 112 or other fire control system(s) in field for fire control purposes such as for target damage assessment. Upon target impact or just prior to target impact, the round could also transmit its impact GPS coordinates, preferably together with its arming status, and a signal indicating detonation and/or impact. The time of the impact can be generally determined by the time of termination of the signal transmission. If the signal continues to be transmitted, then it would be known to the weapon control platform and the operator that the round has not detonated. In either case, if the round detonation confirmation signal has not been received, it would then be known to the fire control system(s) that an unexploded ordinance (UXO) has been generated and where it is located and whether it is armed or disarmed, etc.
The aforementioned transmitted impact GPS coordinates can be used by the weapon control platform to determine if the intended target was hit and if it was not hit, how much correction is to be made to the firing direction. The transmitted impact GPS coordinates can be used to close a feedback loop to provide correction to the gun, mortar, rocket, or the like firing the round. In addition, the aforementioned impact sensory information, such as if a hard or soft target was impacted provide an indication as whether the intended target was hit.
In addition, the personnel monitoring the image viewed on the monitor 116 from the round camera 106 can readily disarm the round if the round does not appear to be heading towards the intended target.
In addition, the operator can provide a GPS coordinate of an intended target to the round and the GPS receiver on board the round can input the round's GPS coordinates to the round's on-board computer to guide the round towards the GPS coordinate of the intended target. In which case, the operator can further override such guidance with the input means 122 while observing the intended target using the camera images.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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A system for guiding a gun-fired or mortared round towards an intended target, the system including a round having: a forward facing image pick-up device for capturing image data; a first transceiver; guidance device for varying a flight path of the round; and a first processor. The system further including a control platform remotely located from the round, the control platform having: a second transceiver; a second processor; an input device; and a display. Where the first processor transmits image data from the image pick-up device through the first transceiver to the second processor through the second transceiver, the second processor transmits guidance information from the second transceiver to the first processor through the first transceiver and the first processor controls the guidance device based on the guidance information to guide the round towards the intended target.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application under 37 CFR 1.53(b) of application Ser. No. 10/496,168, now U.S. Pat. No. 7,175,126 B2 filed May 18, 2004.
FIELD OF THE INVENTION
The present invention refers to a method for producing paper rolls (so-called “logs” in the technical jargon) of various size.
BACKGROUND OF THE INVENTION
The production of logs is known to require the supply of a continuous paper web along a predetermined path. At a point of said path, a discontinuous transverse cut is operated on the web in order to subdivide it into portions or sheets of preset length to be separated by a tear.
The formation of logs implies the use of tubular cardboard spools (commonly referred to as “cores”) on the surface of which a preset amount of glues is distributed to allow the glueing of the first sheet of the log to be formed.
The formation makes also use of winder rollers which drive the core, on which the paper winds up, into rotation.
The process of formation of a log terminates after a preset amount of paper has been wound over the core.
At this point, the formation of the next log is started.
Upon completion of the said formation it is necessary to glue the last sheet of each log on the underlying sheet, to avoid the spontaneous unwinding of the same log. This type of glueing is defined “edge closing”.
To this end, downstream of the unit for the formation of the log a suitable glueing device is provided to which all the formed logs are fed. Each log is to be cut transversally afterwards, to obtain therefrom a plurality of rolls of paper of commercial format.
A rewinding machine for the production of logs is described in details in the patent EP 694020.
The above described technique of forming a log requires therefore an auxiliary device for glueing. This weighs heavily on the running costs and demands more space for the production system.
There are also other considerations to be made on the above technique. One important aspect to be considered relates to the procedure for spreading the glue onto the core, as necessary to fix the first sheet of the log to be formed. On the machines presently known, this procedure is carried out outside the winding region: the glue is distributed onto the cores to be used afterwards for the formation of the log, prior to the same cores entering the region in which they come in contact with the paper web. This operating mode, in the case of a prolonged stop of the machine, may lead to the drying of the glue present onto the cores. It should be understood that such a situation, if not suitably rectified, leads to a faulty process. In fact, on the machines of this type, the operator is bound, under such conditions, to remove manually the core previously glued.
A further consideration, again concerning the glue spread onto the core, refers to the stage in which the size of the log becomes increasingly larger between the winding rollers. The weight of the glue applied onto the core, in the case the latter is distributed longitudinally on a rather thick line, is cause for an “unbalance” of the same core which, when considering the speed involved, may induce strong vibrations on the log in the course of formation. This phenomenon, which can be self-intensifying, may lead to the formation of a log in which the core results out of axis.
SUMMARY OF THE INVENTION
The main object of the present invention is to overcome the previously mentioned drawbacks.
The present invention makes it possible to avoid using gluing devices of “edge closing” type with significant advantages, as far as cost and space are concerned. Moreover, it allows overcoming the said drying and “unbalance” problems above described.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic illustration of a machine which makes it possible to actuate a method according to the invention;
FIG. 2 shows an enlarged detail of the drawing of FIG. 1 ;
FIGS. 3-10 shows schematically a sequence of steps relating to the operation of the machine of FIG. 1 ;
FIG. 11 is a schematic view in longitudinal section of the first means for the application of glue in inoperative or stand-by condition;
FIG. 12 shows the means of FIG. 11 in operative condition;
FIG. 13A is a partial side view of a possible embodiment of the blade for the means of FIGS. 11 and 12 , in which the blade has thin and spaced apart teeth;
FIG. 13B is a front view of the blade of 13 A;
FIG. 14 is a partial side view of a possible embodiment of the blade for the means of FIGS. 11 and 12 , in which the blade has large teeth;
FIG. 14B is a front view of the blade of FIG. 14A ;
FIG. 15A is a partial side view of a possible embodiment of the blade for the means of FIGS. 11 and 12 , in which the blade has a continuous, non-toothed profile;
FIG. 15B is a front view of the blade of FIG. 15A ;
FIG. 16 is a schematic illustration of a further embodiment of a machine which makes it possible to actuate a method according to the invention; and
FIGS. 17-28 schematically show a machine which makes it possible to actuate a method according to the invention, in different sequential operating steps, with a further exemplary embodiment of the guide channel for the cores.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular, FIG. 1 , a method according to the present invention can be actuated by means of a machine comprising:
a station (A) for feeding the cores ( 1 ); a store (M) for housing the cores ( 1 ); means for supplying the station (A) with cores ( 1 ) removed from the store by a chain delivery system (N) extending between the station (M) and station (A); means for feeding and transversally pre-cutting or perforating the paper ( 2 ) by means of a plurality of feeding, driving, and cutting rollers (R 1 , R 2 , R 3 , RA) disposed along a predetermined path which includes also the station (A) for the supply of cores ( 1 ); and means for rolling up the paper ( 2 ) onto the core ( 1 ) by means of two winder rollers (RA, R 4 , R 5 ), the two rollers (R 4 and R 5 ) of which overlap at the outlet of a channel (C) being delimited by a fixed curvilinear guide ( 3 ) and the surface of roller (RA).
The roller (RA) has the dual function of feeding the paper ( 2 ) and winding it onto the core ( 1 ), as will be best described later.
The above said channel (C) delimits the last stretch of the path covered by the paper ( 2 ) and also the path followed by each core ( 1 ) which leaves the core-feeding station (A) and moves towards the exit of channel (C).
Advantageously, according to the invention, first and second means ( 4 , 5 ) are provided for delivering a preset amount of glue onto the surface of each core ( 1 ) introduced into the channel (C). Said glue-delivering means ( 4 , 5 ) act in correspondence of the channel (C) according to a precise sequential order. This provides for the first delivery of the glue to the last sheet of log (RO) in the course of formation and, then, for the delivery of glue intended to attach the first sheet of a new log on a corresponding core ( 1 ) suitably introduced into the channel (C).
As will be best described later on, the delivery of glue by the first and second means ( 4 , 5 ) is alternated by the transit of a perforation line (p) which separates the last sheet of log (RO) in the course of formation from the first sheet of the next log to be formed.
More particularly, and reference being made to the FIGS. 3-10 , the normal operating condition takes place as described below.
After winding a preset number of sheets onto the core ( 1 ) of log (RO) under formation, the lever ( 6 ), which introduces the core ( 1 ) standing by at the station (A) ( FIG. 3 ), operates the introduction of one core ( 1 ) into the channel (C) by rotating about its axis ( 60 ) and pushing the same core from the back ( FIG. 4 ). Upon this stage, the formation of the log (RO) continues on the opposite side of channel (C), so that the paper continues to wind up onto the relevant core ( 1 r ) by means of the winder rollers (RA, R 4 , R 5 ).
The core ( 1 ), freshly introduced into the channel (C), begins to advance and to roll at the same time by virtue of the contact of its surface with the surface of the roller (RA) which rotates about its own axis, as indicated by the arrow (U).
During the step in which the core ( 1 ) is introduced into the channel (C), the angular speed of roller (R 5 ) is decreased with respect to that of roller (RA) and roller (R 4 ). This situation causes the log under formation (RO) to move away from the surface of roller (RA). The angular speed of roller (R 4 ) is then set equal to that of roller (R 5 ). The speed difference between roller (R 5 ) and roller (RA) determines a reduction of tension and, therefore, a loosening of the paper web ( 2 ) upstream of rollers (R 4 , R 5 ) and implies also a detachment of the paper from the surface of roller (RA) ( FIG. 4 ). This detachment occurs along the channel (C) over a length extending between the core ( 1 ) and winder rollers (R 4 , R 5 ). The detachment of the paper from roller (RA) can be made easier by a blow of compressed air through a nozzle ( 7 ) acting between the surface of roller (RA) and the station of the winder rollers (R 4 , R 5 ). As an alternative to the blow operated through the nozzle ( 7 ), a suction may be operated on the side of guide ( 3 ). In the drawings, (VU) denotes a suction unit.
When the core ( 1 ), by virtue of its advancing along the channel (C), arrives in correspondence of the first glue-delivering means ( 4 ), these are activated and, accordingly, a preset amount of glue is applied on the surface of core ( 1 ) ( FIG. 5 ). When this core ( 1 ) arrives in correspondence of the second glue-delivering means ( 5 ), these are activated as well ( FIG. 6 ). The distance between the first ( 4 ) and second ( 5 ) means is properly selected so that, in correspondence of the second means ( 5 ), the core ( 1 ) will result rotated through an angle relative to the position taken up in correspondence of the first means ( 4 ) ( FIG. 6 ). In any case, the perforation line (p) on the paper ( 2 ) results included between the regions (q, a) subjected to the actions of the first and second glue-delivering means ( 4 , 5 ). In this way, the delivery of the glue by the first means ( 4 ) will interest the last sheet of log (RO) under formation, while the delivery of glue by the second means ( 5 ) will cause the glueing on the core ( 1 ) of the first sheet of the new log under formation.
As shown in greater detail in FIG. 6 , when the core ( 1 ), owing to its combined advancement and rolling up along the channel (C), arrives over the second glue-delivering means ( 5 ), the region (q) of paper web ( 2 ) comes in contact with the region of core ( 1 ) previously interested by the action of the first glue-delivering means ( 4 ). Depending on the position of said glue-delivering means ( 4 , 5 ), the region (q) results offset by a well defined angle relative to the region (a) of core ( 1 ) onto which the second means ( 5 ) are made to act.
FIG. 6 shows the case in which the position of said means ( 4 , 5 ) is such that the region (q) and (a), acted upon by means ( 4 , 5 ), result diametrically opposite on the core ( 1 ), so that the said angle is of approximately 180°.
The core ( 1 ), by moving and rolling up forwards along the channel (C), transfers most of its glue, applied by the means ( 4 ), to the region (q′) of the paper web. The region (q) belongs to the last sheet of log (RO) under formation inasmuch as it results downstream of the perforation line (p) which defines the end of the same log (RO). In practice, an edge (q′) of the last sheet of log (RO) under formation results thus glued, that is, provided with glue, at some distance from line (p): the core ( 1 ) makes up the means by which the glue is applied on the last sheet of the log (RO) since, at least in part (though in sufficient amount), the glue is transferred by contact from the core (region q) to the paper (edge or region q′).
By keeping on along its path, the core ( 1 ) passes also the second glue-delivering means ( 5 ) and, by virtue of its rolling up along the channel (C), also the region (a) of the same core ( 1 ) arrives in contact with the paper web ( 2 ), at a region of the sheet which follows the line (p). This sheet is the first one of the subsequent log to be formed. The glue in the region (a) is such as to cause the paper web ( 2 ) to adhere onto the core ( 1 ) which web, in the meantime and as previously mentioned, has become somewhat loose in the region between the core ( 1 ) and the end of the channel (C), by virtue of the reduction of speed of the winder rollers (R 4 , R 5 ) with respect to roller (RA) ( FIG. 7 ).
The loosening effect of the paper web ( 2 ), in combination with the adhesion of the same web onto the core ( 1 ) caused by the glue present in the region (a), is such that, during the rolling up of core ( 1 ), there occurs a progressive winding of the paper web ( 2 ) onto the core ( 1 ) ( FIG. 7 ). Thereafter, in correspondence of the terminal portion ( 30 ) of the guide ( 3 ), the first sheet of the next log to be formed results fitted (again by the effect of rolling and advancement of core ( 1 )) between the surface of the said portion ( 30 ) and the surface of core ( 1 ) (see FIG. 8 ). Owing to this, and to the fact that the winder rollers (R 4 , R 5 ) keep on rotating, the part of the paper web ( 2 ) which results compressed between the surface ( 30 ) of guide ( 3 ) and the log (RO) under formation is subjected to such a tensioning as to cause a tear in correspondence of the line (p), as shown in FIG. 9 .
By keeping on to rotate, the winder rollers (R 4 , R 5 ) complete the formation of the log (RO) with the passage of the glued region (q′) of the log's last sheet under the roller (R 4 ). This causes the corresponding glueing of the last sheet of log (RO) upon that immediately below of the same log ( FIG. 10 ). At this point, the speed of roller (R 4 ) is increased and, by virtue of the speed difference thus created between the winder rollers (R 4 , R 5 ), the log (RO) under formation is released and made to slide along a discharge guide ( 9 ) downstream of the winder rollers (R 4 , R 5 ). Following this step, the rollers (R 4 , R 5 ) reach again the running speed, and the place of (RO) is taken by the core ( 1 ) advancing towards the end part ( 30 ) of the guide ( 3 ) to allow the formation of a new log.
It will be appreciated that the interventions of said first and second glue-delivering means are suitably synchronized to each other to obtaining what has been previously described, and that the paper ( 2 ) is supplied with continuity onto the surface of the roller (RA) also during the advancement of the core ( 1 ) along the channel (C).
The winder roller (R 4 ) is mounted on a corresponding support arm ( 400 ) which is hinged to a stationary part of the machine and is associated with an actuator ( 410 ) which allows it to be moved close to, and away from the lower winder roller (R 5 ) in a manner known to those skilled in the art.
The above described operations can be performed automatically through programmable electronic means known to those skilled in the art and, therefore, will not be described in greater details.
From the above description of the machine and operating procedure it can be seen that it is possible to avoid using any gluing device downstream of the winder rollers, with evident economical advantages derived both from direct savings and the smaller space required for the plant. Also evident are the advantages derived from the novel system of transferring the glue onto the core: the glueing carried out within the winding region overcomes the problems due to the drying of the glue (which glue, by fulfilling immediately its function, is not subject to dry), and the application of a dual longitudinal line reduces the “unbalance” problems, as the regions of glue application form substantially two lines diametrically opposite with respect to the surface of the core ( 1 ).
The first glue-application means ( 4 ) may comprise, with reference to the examples of FIGS. 11 and 12 , a liquid-glue-holding reservoir ( 40 ) located below the guide ( 3 ), and a blade ( 41 ) provided inside said reservoir and movable from and to the channel (C) under control of a corresponding actuator ( 42 ) connected thereto via a chain of rigid transmissions ( 43 , 44 , 45 ). In the condition shown in FIG. 11 , the blade ( 41 ) is fully held within the reservoir ( 40 ). In the condition shown in FIG. 12 , the blade ( 41 ) is lifted by the withdrawal of the rod of actuator ( 42 ) and by the corresponding movements (as shown by the arrows) of members ( 43 , 44 , 45 ) of the transmission system. The lifting of blade ( 41 ) causes the application of the glue upon the surface of core ( 1 ) which, on that moment, is transiting along the channel (C). It will be appreciated that the guide ( 3 ) is suitably slotted to allow the lifting of the blade ( 41 ) and the contact thereof with the surface of blade ( 1 ). As illustrated in FIGS. 13A , 14 A and 15 A, the upper edge of the blade ( 41 ) may be either discontinuous, that is, provided with a toothing ( FIGS. 13A and 14A ), or continuous ( FIG. 15A ). Besides, as shown in FIGS. 13B , 14 B and 15 B, the upper edge of the blade ( 41 ) may be concave, with concavity turning upwards.
The second glue-application means ( 5 ) can be made like the first ones ( 4 ) and their description, therefore, will not be repeated.
Obviously, the number of sheets of each log (RO) and the length thereof may be as desired.
According to a further embodiment of the present invention, and with reference to FIG. 16 , the glue can be delivered through two injectors ( 32 , 31 ) intended for delivering the glue direct onto the paper ( 2 ) upstream and respectively downstream of a perforation line (p) which separates the last sheet of log (RO) under formation from the first sheet of the next log to be formed. The activation of said injectors ( 32 , 31 ) can be concurrent, as schematically illustrated in FIG. 16 .
As in the case previously described, the injectors ( 32 , 31 ) are positioned within said channel (C) at a preset distance one from the other.
With reference to the examples of FIGS. 17-28 , the stationary guide of said channel (C) is into two elements:
a first element ( 3 a ) is opposite to an underlying conveyor belt ( 300 ) ring-like closed and located immediately downstream of the section (A) which feeds the tubular cores ( 1 ); a second element ( 3 b ) is located downstream of the first element ( 3 a ) and of said belt ( 300 ), opposite to roller (RA). The schematic representations of FIGS. 17-22 and respectively of FIGS. 23-28 differ from each other only for the different positioning of the glue-delivering means which, in any case, act within the said channel (C) and are positioned at a preset distance from each other.
The glue-delivering procedures can be combined as in FIGS. 17-22 where the first glue-delivering means are of blade type, and the second delivering means are of injection type.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A method for producing logs of paper comprises:
feeding a continuous paper web along a fixed path; transversely perforating the paper web such that the paper can be subdivided into various lengths and detached by tearing; feeding tubes such that a preset number of sheets are wound onto said tube to form a log, the tubes being guided in a tube-guiding channel extending between a tube-feeding station and a log-forming station, the channel being delimited in part by a fixed guide and in part by a roller for feeding the paper; and applying glue within the channel such that the last sheet is glued to the log being formed and the paper web is glued to the next tube.
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TECHNICAL FIELD OF THE INVENTION
The present invention generally relates to a hinged slide rail structure for cabinets, and more particularly to a hinged slide rail structure that comprises a buffering device arranged between a hinge and a rail to reduce the noise induced in closing a cabinet door and protect a user from being clamped and hurt by a closing door.
DESCRIPTION OF THE PRIOR ART
Offices, laboratories, or various work sites are often provided with cabinets or lockers for storage and organization of articles. The cabinets are often provided with a door, which can turn upward or sideways, or slide sideways, for covering and closing a storage space inside the cabinet in order to realize protection and storage of the article.
A regular cabinet that is mounted to a wall uses a hinge connecting between the cabinet door panel and the cabinet body to allow the door panel to turn upward for opening. However, the door panel may be caused to swing downward due to gravity acting thereon, leading to undesired inconvenience of use. To overcome such a problem, a hinged slide rail is available in the market. As shown in FIG. 1 of the attached drawings, a hinged slide rail 10 comprises a rail 11 that has a movable plate 111 to which a hinge 12 is mounted. The rail 11 is mounted to an inside surface of a door panel 21 . The hinge 12 has a movable blade 121 that is mounted to an access opening of the cabinet body 20 so as to connect the hinge 12 between the door panel 21 and the cabinet body 20 . With the hinge 12 , the door panel 21 may turn upward with respect to the cabinet body 20 . After the door panel 21 is lifted upward, the door panel 21 can slide on a surface of the cabinet body 20 in order to horizontally position on the cabinet body 20 , preventing the door panel 20 from falling and thus causing inconvenience of use. However, the operation of the hinged slide rail 10 is still disadvantageous. When the door panel 21 is pulled out, it is still subjected to the action of the gravity and thus falls down to induce a noise of impact and clamp and hurt the user.
To solve the problem, Taiwan Utility Model No. M352378 discloses a slide rail slow descending device, which is shown in FIG. 2 of the attached drawings. The slide rail slow descending device 30 comprises a hinge 31 , a fixed rail 32 , a telescopic buffering device 33 , a movable rail 34 , and a swinging element 35 . The hinge 31 has an end fixed to a cabinet 40 that has an access opening. The fixed rail 32 has an end fixed to an opposite end of the hinge 31 . The telescopic buffering device 33 has an end fixed to an opposite end of the fixed rail 32 and an opposite end fixed to the hinge 31 . The movable rail 34 is reciprocally and slidably mounted to the fixed rail 32 and is connected to a door panel 41 . The swinging element 35 is rotatably coupled between the hinge 31 and an outer side of the movable rail 34 . The swinging element 35 comprises a friction section (not labeled) to abrade the outside surface of the movable rail 34 . The outside surface of the movable rail 34 that corresponds to the friction section forms a recess (not shown). Through the buffering effect provided by the telescope buffering device 33 and the friction force between the swinging element 35 and the movable rail 34 , the opening of the door panel 41 is made easy and convenient and effect of silencing and slow descending is realized in the closing of the door panel to avoid clamping and thus hurting users. However, the operation smoothness of sliding of the slide rail slow descending device 30 is heavily dependent upon the friction force between the swinging element 35 and the movable rail 34 , and the movement stroke of the telescopic buffering device 33 imposes a great influence on the opening degree of the door panel 41 . In the opening degree is over-limited or over-excessive, then inconvenience may be caused for the use and operation thereof, or even leading to damage of the door panel 41 or the cabinet body 40 .
Thus, the present invention aims to provide a hinged slide rail with buffering function, which is provided with a movement limiting structure to control the opening angle of a door panel to eliminate any possible inconvenience caused in the operation thereof, so as to overcome the above discussed problems.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a hinged slide rail with buffering function for enhancing the convenience of use.
Another objective of the present invention is to provide a hinged slide rail with buffering function, which provides an effect of slow descending in closing a door panel so as to protect a user from being clamped and hurt and to eliminate the generation of noise.
To achieve the above objectives, the present invention provides a hinged slide rail comprising a rail, a hinge, a retention frame, and a buffering device. The rail comprises a fixed plate, a balled plate, and a movable plate. The balled plate and the movable plate are accommodated in the fixed plate, while the fixed plate is mounted to an inside surface of a door panel. The hinge comprises a movable blade and a fixed blade that are rotatably coupled to each other. The fixed blade is fixed to an end of the movable plate. The movable blade has an end to which a pull bar is mounted. The retention frames mounted to an end of the fixed blade of the hinge and defines therein an accommodation space. The retention frame has an end opposite to the accommodation space and forming two parallel limiting slots. The buffering device is selected among a pneumatic device, a hydraulic device, and a pneumatic/hydraulic device. The buffering device comprises an active rod having an end forming a limiting block that is slidably received in the limiting slots of the retention frame. The limiting block is coupled to the pull bar of the movable blade.
To install, the fixed plate of the rail is mounted to an inside surface of the door panel and the movable blade of the hinge is attached to an access opening of a cabinet body. When the door panel is being opened, the door panel is turned upward rotated as being supported by the pivot between the fixed blade and the movable blade of the hinge. The pull bar of the movable blade drives the limiting block to extend the active rod outward, so that the limiting block is caused to slide to an end of the limiting slots of the retention frame, making the door panel parallel to a top surface of the cabinet body. The door panel may then be pushed toward the rear side of the cabinet body so as to realize opening and stowing the door panel in a space above the top of the cabinet body. The operation is convenient and the door panel does not unexpectedly close when an article is being removed out of the cabinet, making it safe in operation and use. To close the door panel, the door panel is first pulled forward and the door panel is acted by a downward force induced by gravity. The buffering device functions to slow down the downward movement of the door panel and to allow the door panel to close gently, so as to eliminate the problem of noise generation and clamping and hurting users.
The foregoing objectives and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the installation of a conventional hinged slide rail.
FIG. 2 is a schematic view illustrating the installation of a device disclosed in Taiwan Utility Model No. M352378.
FIG. 3 is an exploded view of a preferred embodiment of the present invention.
FIG. 4 is a perspective view of the preferred embodiment of the present invention in an assembled form.
FIG. 5 is a schematic view illustrating the operation of the preferred embodiment in an initial phase of opening a door panel.
FIG. 6 is a schematic view illustrating the operation of the preferred embodiment in a subsequent phase of opening a door panel.
FIG. 7 is a schematic view illustrating the operation of the preferred embodiment of closing a door panel.
FIG. 8 is a perspective view illustrating another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following descriptions are exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes to the described embodiments may be made in the function and arrangement of the elements described without departing from the scope of the invention as set forth in the appended claims.
Referring to FIGS. 3 and 4 , which shows exploded and perspective views of the present invention, the present invention comprises the following constituent components:
A rail 50 comprises at least a fixed plate 51 , a balled plate 52 , and a movable plate 53 . The balled plate 52 is interposed between the movable plate 53 and the fixed plate 51 to enhance lubrication effect between the movable plate 53 and the fixed plate 51 so as not only to allow the movable plate 53 to do reciprocal sliding movement with respect to the fixed plate 51 but also making the sliding movement smooth. The rail 50 comprises a roller 54 set at one end thereof.
A hinge 60 comprises a movable blade 61 and a fixed blade 62 that are rotatably coupled to each other so that the movable blade 61 is reciprocally rotatable with respect to the fixed blade 62 . The fixed blade 62 is fixed to an end of the movable plate 53 of the rail 50 . The movable blade has an opposite end to which a pull bar 611 is rotatably mounted. The movable blade 61 of the hinge forms a plurality of fixing holes 612 .
A retention frame 70 has a central portion forming a cylindrical accommodation space 71 of which two sides forming lugs 72 extending therefrom to be substantially parallel to each other. The lugs 72 form at least one fixing hole 721 and one limiting slot 722 and the two limiting slots 722 are substantially parallel to each other. By inserting screws 73 through the fixing holes 721 , the retention frame 70 is fixed to the movable plate 53 of the rail 50 .
A buffering device 80 is selected from a group consisting of a pneumatic device, a hydraulic device, and a pneumatic/hydraulic device. In the instant embodiment, the buffering device 80 comprises a pneumatic/hydraulic device. The buffering device 80 is received in the accommodation space 71 of the retention frame 70 and has an end forming an active rod 81 . The active rod 81 has an end forming a limiting block 82 that is slidably received in the limiting slots 722 . The limiting block 82 is coupled to the pull bar 611 of the movable blade 61 to have the active rod 81 of the buffering device 80 set in a normally contracted condition and set the limiting block 82 at an innermost end of the limiting slots 722 .
When the movable blade 61 of the hinge 60 is doing reciprocal rotation, the active rod 81 of the buffering device 80 is driven to extend/contract and thus causing the limiting block 82 to reciprocally slide within the limiting slots 722 , so as to control an opening range of the hinge 60 . (In the instant embodiment, the movable blade 61 of the hinge 60 can take a relative rotation of 0-90 degrees with respect to the fixed blade 62 .)
Referring to FIGS. 3 and 5 - 7 , the present invention can be installed on a locker or cabinet 90 mounted on a wall. The fixed plate 51 of the rail 50 is mounted to an inside surface of a door panel 92 and the movable blade 61 of the hinge 60 is attached to an access opening of a cabinet body 91 . Thus, when the door panel 92 is opened, the door panel 92 is rotated upward as being supported by the pivot between the fixed blade 62 and the movable blade 61 of the hinge 60 , thereby causing the movable blade 61 to rotate upward. The pull bar 611 of the movable blade 61 drives the limiting block 82 to slide outward and extends the active rod 81 of the buffering device 80 (under the action of air pressure inside the buffering device 80 ), so that the limiting block 82 is caused to slide to an end of the limiting slots 722 of the retention frame 70 , making the door panel 92 parallel to a top surface of the cabinet body 91 . Afterwards, a user may push the door panel rearward, and the movable plate 53 of the rail 60 is caused to slide with respect to the fixed plate, moving the door panel 92 toward the rear side of the cabinet body 91 . In this way, opening and stowing the door panel 92 in a space above the top of the cabinet body 91 is realized. The operation is easy and the door panel 92 does not unexpectedly close when the cabinet is being accessed, making it safe in operation and use and also effort-saving. To close the door panel 92 , the door panel 92 is first pulled forward and the door panel 92 is acted by a downward force induced by gravity to overcome the hydraulic force of the buffering device 80 so as to slowly close. The present invention uses the buffering device 80 to reduce the downward moving speed of the door panel 92 to make the door panel 92 closed in a gentle manner. Thus, no noise and damage to a user may occur.
Referring to FIGS. 5-8 , in another embodiment, to enhance the practicability of the present invention and to provide the convenience of effort-saved operation, a tension spring 55 is arranged between the fixed blade 62 of the hinge 60 and the fixed plate 51 of the rail 50 . The fixed blade 62 comprises a retention peg 621 . One side of the fixed plate 51 forms a retention peg 511 . Opposite ends of the spring 55 are respectively attached to the two retention pegs 621 , 511 . When the door panel 92 is pushed rearward, the returning spring force of the spring 55 helps reducing the force needed in pushing the door panel 92 rearward.
Having been described the present invention above, it is apparent that the present invention offers the following advantages:
(1) The present invention arranges a buffering device 80 between the rail 50 and the hinge 60 to buffer the downward movement and force of the door panel 92 in order to eliminate the problems of clamping and hurting people and generation of noise. The buffering device 80 also helps saving effort for opening the door panel 92 .
(2) The present invention provides a retention frame 70 that forms limiting slots 722 for limiting the distance range that a limiting block 80 coupled to the hinge 60 , so as to control the opening range of the door panel 92 .
(3) The present invention arranges a tension spring 55 between the rail 50 and the hinge 60 , which helps reducing the force needed in pushing the sliding movement of the door panel 92 .
It is noted that what described above shows only a preferred embodiment of the present invention and does not intend to limit the scope of the present invention. For example, modification made on the type of the rail 50 or the type of the hinge 60 or the buffering device 80 is considered within the scope of the present invention. Thus, any modification that can be readily achieved by those having ordinary skills, such as replacing the pneumatic/hydraulic device of the buffering device 80 with a regular pneumatic device or a hydraulic device, is considered within the scope of the present invention as defined in the appended claims.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
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A hinged slide rail with buffering function, which includes a rail to which a hinge is mounted. The hinge has a movable blade and a fixed blade between which a buffering device is coupled. The buffering device is housed in a retention frame. The retention frame has an end forming a limiting structure. The buffering device has an active rod coupled to the limiting structure. The movable blade includes a pull bar that is connected to the limiting structure. The hinged slide rail is installed between a door panel and a body of a cabinet to remarkably enhance the convenience of operation and eliminates the potential problems of generating noise and clamping and hurting users.
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BACKGROUND OF THE INVENTION
The present invention relates in general to the packaging art, and is more particularly concerned with improvements in the sealing and cutoff means in forms, fill and seal machines wherein packages are formed from zippered foil or film material.
Numerous and varied sealing and cutoff mechanisms for form fill and seal machines are known. By way of example, U.S. Pat. Nos. 4,727,709 and 4,745,731 are referred to and which disclose forms of sealing and cutoff mechanisms wherein separate sealing bars and separate cutoff means are provided. The disclosures of these patents are incorporated herein to any extent necessary for full understanding of the present invention in relation to details not disclosed herein because conventional.
One of the problems that has been prevalent in prior apparatus has been the difficulty in attainment of leak-proof securement of the extruded plastic zipper in the packages produced by the machines. An expedient that has been used heretofore is ultrasonic pre-welding of the zipper in order to avoid leakage at the opposite ends of the zipper in the packages.
Another problem has been the general complexity of the cut-off and sealing mechanisms, especially in form, fill and seal machines which use zippered foil or film.
SUMMARY OF THE PRESENT INVENTION
An important object of the present invention is to provide a new and improved sealing jaw means for package making machines, and especially useful with form, fill and seal machines.
Another object of the invention is to provide a new and improved sealing jaw and method for attaining leak-proof securement of the plastic zippers in packages produced from zippered foil or film.
A further object of the invention is to provide a new and improved combined sealing and cutoff jaw structure and method, especially, but not exclusively, useful for form, fill and seal packaging machines.
Pursuant to the present invention, there is provided a new and improved sealing jaw arrangement for securing zippered package making foil or film material and comprising a pair of cyclically cooperating sealing jaws for receiving the material therebetween, one of the jaws carrying a pair of spaced sealing ribs and a sealing surface between the ribs, and the other of the jaws having means cooperating with the sealing surface for sealing the material. One of the jaws desirably provides a mount for a cutoff knife, and the other of the jaws has means for receiving the knife in a package cutoff stroke substantially coincident with the sealing cycle of the sealing jaws.
There is also provided a method of end sealing and cutoff which may be practiced with the foregoing apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which:
FIG. 1 is a more or less schematic, fragmentary perspective view of sealing and cutoff mechanism embodying the present invention and showing the complementary sealing jaws thereof in the open or separated relation;
FIG. 2 is a fragmentary sectional detail view showing the jaws of FIG. 1 in the closed sealing and cutoff relation in the cycle of operation;
FIG. 3 is a fragmentary perspective view of the sealing face of one of the jaws;
FIG. 4 is a more or less schematic end elevational view of a slight modification of the sealing jaws; and
FIG. 5 is a fragmental elevational view taken substantially along the line V--V in FIG. 4.
DETAILED DESCRIPTION
As shown in FIG. 1, an end sealing jaw mechanism 10 may be located at a desired distance below the discharge or nozzle end of a forming or filling tube 11 of a form, fill and seal machine for cyclically securing into successive bags or packages package-making foil or film material 12 which has been in known manner wrapped about and advanced along the tube 11. An extruded plastic, profiled reclosable zipper 13 on the material is shown closed for conversion of the material into packages to be filled and sealed.
According to the present invention, the jaw mechanism 10 comprises a pair of cyclically cooperating sealing jaws 14 and 15 desirably in the form of unitary bars for receiving the material 12 therebetween. Any preferred means may be employed for controlling and guiding the jaws 14 and 15 cyclically from the spaced apart relation shown in FIG. 1 into the cooperatively pressed together sealing relation shown in FIG. 2 and return, coordinated with the operating cycles of the associated machine. In this instance, the jaws 14 and 15 are shown as mounted on fixed guide rods 17 which bracket the package making material 12 in spaced relation. The sealing bars 14 and 15 are reciprocatable along the guide rods 17 by driving means schematically represented by arrows 18 and which may comprise any known mechanism for the purpose, such as linkages, mechanical or fluid actuated operators, and the like.
A principal function of the sealing bars 14 and 15 is to effect end sealing of the package making material 12 for, as is customary, closingly sealing the upper side of the lead package which has been filled, and simultaneously sealing the end of the material 12 for closing the lower side of the next succeeding package.
Each of the sealing bars 14 and 15 is equipped with means, such as heaters 19, by which the temperature of the sealing bars is maintained, during operation, at a heat which will effect sealing of the foil or film material 12 and the zipper 13 when the jaws 14 and 15 are brought into the sealing cooperation shown in FIG. 2 from the spaced apart condition shown in FIG. 1, in a cycle of operation of the jaws.
For effecting a solid, permanent sealing of the material 12, including the zipper 13, in each contiguous package side portion during a cyclical sealing stroke of the jaws 14 and 15, one of the jaws, herein the jaw 14, is provided with means including spaced parallel projecting sealing ribs 20, each of which preferably has a smoothly rounded crown sealing profile 21. Although the ribs 20 may be formed integrally in one piece with the block providing the jaw 14, for fabrication convenience the ribs 20 are formed as bars fixedly set into respectively complementary grooves 22 to a depth which will permit the rounded sealing crowns 21 of the ribs to project a desired distance from the associated sealing surface of the sealing bar 14.
For accommodating the sealing ribs 21, without unduly thinning the material 12 between the bars 14 and 15 at the ribs 20 beyond the thinning effected between the remaining sealing faces of the bars, the sealing bar 15 is provided with means cooperating with the ribs 20, herein comprising complementary groove depressions 23 of arcuate shape complementary to the rib crowns 21 and within which the ribs engage in the sealing stroke of the bars 14 and 15.
Desirably at each of the outer sides of the ribs 20 and the sealing grooves 23, the bars have chamfered lead-in surfaces 24 along their upper edges and corresponding chamfered lead-out surfaces 25 along their lower edges to avoid any hangup of the package making material 12.
Between the ribs 20, the opposed sealing faces of the bars 14 and 15 are provided with serration die surfaces 27 with the serrations running generally transversely for providing corresponding seals in the package edge portions sealingly engaged by the surfaces 27.
In addition to their sealing function, the ribs 20 and complementary grooves 23 serve in the sealing mode or relation of the jaws 14 and 15 to anchor the portion of the package material located between the cooperating ribs an grooves against displacement longitudinally of the material 12 during severance of the thus anchored portion of the material as by means of a cutoff knife 28. Conveniently, the knife 28 comprises a blade member having a sharp edge 29 and is of a length at least equal to the full width of the flattened package material 12 gripped between the sealing jaws 14 and 15. The blade member 28 is accommodated slidably in a groove 30 in the face of one of the jaw members, herein the number 14. The groove 30 is of sufficient depth to permit the knife member 28 to be reciprocated from a clearance position as shown in dash outline in FIG. 2, clear of the package making material when first gripped by the jaws 14 and 15, into the full line position wherein the material held taut between the ribs 20 is severed by the knife edge 29. For effecting such reciprocation out of and then returned to the groove 30, an actuator 31 is connected to the back of the blade member 28 and projects through a bore 32 which communicates from the back of the jaw member 14 with the groove 30 for working attachment to the blade member 28. Suitable power means such as fluid operated actuator, linkage or the like represented by the directional arrow 33 operates the actuator 31 in timed relation to the cyclical operation of the jaws 14 and 15.
To facilitate the cutoff procedure, the other of the jaws, namely the jaw 15 is provided with cushioning means comprising a bar-like anvil member 34 which is slidably accommodated in a complementary groove 35 in the jaw member 15 and is biased by means such as compression spring or springs 37 so as to be yieldable when engaged by the knife edge 29. To minimize wear on the knife edge 29, the anvil bar 34 is desirably formed from a suitable wear resistant plastic material such as rigid nylon, polytetrafluoroethylene, or the like.
To avoid escape of the anvil member 34 from the groove 35, the anvil member may be provided at its inner edge with retaining shoulders 38 engageable with complementary stop shoulders 39 on the jaw member 15 defined within an enlargement of the groove 35.
In the modification in FIGS. 4 and 5, the structure of the sealing jaw mechanism 10' is substantially the same as in the mechanism 10 accept for the sealing faces of jaw members 14' and 15' which have serration die surfaces 27' which extend to both sides of the ribs 20' and the complementary grooves 23', where that is a desired configuration. In this instance only the lower sides of the jaw members 14' and 15' are provided with chamfers 25', although if preferred the upper side may also be thus provided. The lower side has the chamfer 25' to avoid interference with the product loaded and thus substantially bulged lower, lead packages sealed and cutoff in the mechanism 10' wherein the package making material is, similarly as in the mechanism 10, sealed as described, and cutoff by means of the blade 28' cushioned against the spring loaded yieldable anvil 34' functioning the same as described in connection with the mechanism 10.
It will be understood that variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the present invention.
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Sealing jaw structure and method for securing zippered package making foil or film material, comprising sealing jaws, one of which carries a pair of spaced material engaging ribs for not only sealing but also tightening the material between the ribs during sealing cooperation of the jaws. The tightening facilitates cutting of the material being engaged between the jaws by a knife carried reciprocably by the jaw that carries the ribs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to and claims the benefit of priority of U.S. Provisional Patent Application No. 60/694,746 entitled “High-Efficiency Thermoelectric Waste Energy Recovery System for Passenger Vehicle Applications,” filed Jun. 28, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED R&D
The U.S. Government may claim to have certain rights in this invention or parts of this invention under Contract No. DE-FC26-04NT42279 awarded by the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application relates to the field of thermoelectric power generation, and more particularly to systems for improving the generation of power from thermoelectrics, particularly in the situation where there are limitations in the system on the temperature differential across the thermoelectric.
2. Description of the Related Art
Thermoelectrics are solid state devices that operate to become cold on one side and hot on the other side when electrical current passes through. They can also generate power by maintaining a temperature differential across the thermoelectric. Under many operating conditions, however, thermoelectric power generators are exposed to a combination of changing heat fluxes, hot side heat source temperatures, cold side temperatures, and other variable conditions. In addition, the device properties, such as TE thermal conductance, figure of merit Z, heat exchanger performance all have a range that can combine to, in general, reduce device performance. As a result, performance varies and operation at a predetermined set point can lead to performance degradation compared to the design.
Any process that consumes energy that is not 100% efficient generates waste energy, often in the form of heat. For example, engines generate a substantial amount of waste heat, representing inefficiency in the engine. Various ways to attempt to capture and use some of this waste heat have been considered in order to improve the efficiency of any type of engine, such as the engine in automobiles. Placing thermoelectrics on the exhaust system of an automobile has been contemplated (See U.S. Pat. No. 6,986,247 entitled Thermoelectric Catalytic Power Generator with Preheat). However, the exhaust system varies greatly in temperatures and heat flux. Thus, because a thermoelectric generator is typically designed to operate effectively over a small range of hot side temperatures, using exhaust for the hot side of a thermoelectric generator is suboptimal. In addition, a logical cold side coolant for a thermoelectric generator linked to an engine system is the engine coolant already provided. However, the coolant needs to be maintained at a fairly hot temperature for efficient engine operation. Thus, using the existing coolant limits the temperature gradient that can be established across the thermoelectric generator, thereby limiting effective waste heat recovery.
SUMMARY OF THE INVENTION
Thermoelectric (TE) power generation from waste heat has suffered for many reasons in the past. The described invention addresses some of these delinquencies, greatly improving the capability of the TE generator. The improvement is generally obtained by providing an intermediate loop for the cool side, for the hot side or for both, and in one embodiment, providing advanced control for the intermediate loop or loops. Due to the great variability of the waste heat generated from an automobile engine, the present invention is presented in the context of a thermoelectric generation system using waste heat from an engine of an automobile as the thermal power source. This example permits an effective disclosure of the features of the invention. However, the present invention is not limited to thermoelectric generators for automobiles, or even for engines. The present invention has application in any thermoelectric generation system.
To effectively maximize the performance of a waste heat recovery system using thermoelectrics, maintaining the highest temperature differential across the thermoelectric generator module (TGM) is generally ideal. One way to do this is to keep the hot-side temperatures as high as possible. Another method is to better control the cold-side temperatures. By using an intermediate heat transfer loop and appropriate control for that loop for the hot side, the cold side, or both, significant improvements to power production and/or efficiency are obtained.
In the past (See U.S. Pat. No. 6,986,247), TE modules have been proposed as a lining around pipes or tubes carrying hot fluid, such as the exhaust system of an automobile. This provides intimate contact between the hot fluid and the TE material, which is desirable to maximize the hot-side temperature of the TE material as well as the temperature difference across the TE material. This may be fine or even optimal for a static system where the hot fluid flow rates and temperatures do not change. The TE elements can be designed to provide a perfect impedance match with the hot fluid flow. This impedance match is important since element geometry can greatly affect the amount of heat that can be effectively transferred through the TE elements. For a static system, the thermoelectric system can be designed for steady state operation at maximum efficiency or maximum power output or a combination acceptable to the designer.
However, once the system becomes dynamic, as in the case of an automobile driven by an engine, where the range of temperatures and heat flux vary greatly, a thermoelectric generation system designed for a particular set of conditions may only produce a small fraction of its capacity, or even become negative under certain operating conditions. In the present invention, by providing a separate heat transfer loop for the cold side, the hot side or both, and appropriate control for such loop or loops, substantial improvements are obtained making such systems feasible in actual use.
One aspect of the present invention involves a thermoelectric power generation system. The system has a thermoelectric generator having thermoelectrics with at least one cold side and at least one hot side configured to generate electrical power when a temperature gradient is present between said at least one cold side and said at least one hot side. An intermediate heat transfer loop is in thermal communication with said at least one hot side and is in thermal communication with at least one main heat source. A controller is in communication with flow control devices in said intermediate heat transfer loop and is adapted to control the heat flow in the intermediate heat transfer loop in response to changes in heat originating from the at least one main heat source.
In one embodiment, the system further comprises thermal storage. The thermal storage may be in the intermediate loop, associated with the main heat source or associated with both the intermediate loop and the main heat source. Advantageously, a heat exchanger between the intermediate heat transfer loop and the main heat source facilitates the movement of thermal power from the main heat source to the intermediate heat transfer loop. Preferably, a heat exchanger bypass is controllable via the controller to cause some or all of the heat from the main heat source to bypass the heat exchanger, depending on the heat from the main heat source and the capacity of the thermoelectrics.
Another aspect of the present invention involves a thermoelectric power generation system for a main heat source. A thermoelectric generator has thermoelectrics with at least one cold side and at least one hot side configured to generate electrical power when a temperature gradient is present across said at least one cold side and said at least one hot side. An intermediate heat transfer loop is preferably in thermal communication with said at least one cold side and in communication with at least one heat dissipation device. Preferably, the heat dissipation device is separate from a main heat source. A controller in communication with flow control devices in said intermediate heat transfer loop is adaptive to control the heat flow in the intermediate heat transfer loop in response to changes in operating conditions for the thermoelectrics and/or the heat output from the main heat source.
In one embodiment, the heat source is an engine, having a main coolant system. Preferably, the intermediate heat transfer loop can be thermally connectable to the main coolant system of the engine, such that during engine warm-up, heat transferred from the thermoelectrics to the intermediate heat transfer loop is further transferred to the main cooling system for the engine, thereby decreasing warm-up time for the engine. Further, a heat exchanger is advantageously provided between the intermediate heat transfer loop and the main heat source, with an optional a heat exchanger bypass controllable via the controller, to cause some or all of the heat from the main heat source to bypass the heat exchanger.
Yet another aspect of the present invention involves a method of generating power from waste heat from a main heat source using a thermoelectric generator having thermoelectrics with at least one cold side and at least one hot side configured to generate electrical power when a temperature gradient is present across said at least one cold side and said at least one hot side. The method involves transferring heat from the main heat source to an intermediate heat transfer loop, where the intermediate heat transfer loop is in thermal communication with a heat dissipation device. The flow of heat is controlled in the intermediate heat transfer loop in response to changes in operating conditions of the main heat source.
In one embodiment, the heat source is an engine, having a main coolant system. In this embodiment, preferably, the intermediate heat transfer loop can be thermally connectable to the main coolant system of the engine. Thereby, during engine warm-up, heat is transferred transferring from the thermoelectrics to the intermediate heat transfer loop and further to the main coolant system for the engine, thereby decreasing warm-up time for the engine.
In one embodiment, the flow of heat from the main heat source to the intermediate loop is controlled based on changing heat flux of the main heat source and the capacity of the thermoelectric generator.
Further aspects and features of the invention are disclosed in connection with the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a thermoelectric generation system with a cold-side intermediate heat transfer loop.
FIG. 2 illustrates another embodiment of a thermoelectric generation system with an cold-side intermediate heat transfer loop.
FIG. 3 illustrates a thermoelectric generation system with a hot-side intermediate heat transfer loop.
FIG. 4 illustrates another embodiment of a thermoelectric generation system with a hot-side intermediate heat transfer loop, similar to that depicted in FIG. 3 , but with added heat capacity storage.
FIG. 5 illustrates another embodiment of a thermoelectric generation system with a hot-side intermediate heat transfer loop, similar to that depicted in FIG. 3 , but with added heat capacity storage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Automotive waste heat recovery is used as an example of the present invention. However, the invention is applicable to improve the performance of power generation, waste heat recovery, cogeneration, power production augmentation, and other uses. As further examples, the present invention can be used to utilize waste heat in the engine coolant, transmission oil, brakes, catalytic converters, and other sources in cars, trucks, busses, trains, aircraft and other vehicles. Similarly, waste heat from chemical processes, glass manufacture, cement manufacture, and other industrial processes can be utilized. Other sources of waste heat such as from biowaste, trash incineration, burn off from refuse dumps, oil well burn off, can be used. Power can be produced from solar, nuclear, geothermal and other heat sources. Application to portable, primary, standby, emergency, remote, personal and other power production devices are also part of this invention. In addition, the present invention can be coupled to other devices in cogeneration systems, such as photovoltaic, fuel cell, fuel cell reformers, nuclear, internal, external and catalytic combustors, and other advantageous cogeneration systems. It should also be understood that the number of TE modules described in any embodiment herein is not of any import, but is merely selected to illustrate the invention.
The present invention is introduced using examples and particular embodiments for descriptive and illustrative purposes. Although examples are presented to show how various configurations can be employed to achieve the desired improvements, the particular embodiments are only illustrative and not intended in any way to restrict the inventions presented. It should also be noted that the term thermoelectric or thermoelectric element as used herein can mean individual thermoelectric elements as well as a collection of elements or arrays of elements. Further, the term thermoelectric is not restrictive, but used to include thermoionic and all other solid-state cooling and heating devices. In addition, the terms hot and cool or cold are relative to each other and do not indicate any particular temperature relative to room temperature or the like. Finally, the term working fluid is not limited to a single fluid, but can refer to one or more working fluids.
Cold Side Intermediate Loop
The cold-side temperatures that the theremoelectric generator module (TGM) are exposed to are often controlled by a cold-side loop. In the context of an engine, this cold-side loop can be the traditional vehicle radiator coolant loop, a stand-alone coolant loop or heat dissipator, or a combination of both. The radiator cooling loop has the advantage that it is already available. Little additional design work may be needed. The capacity of the coolant loop would merely need to be sufficient to handle the additional heat that would be dumped into it from the waste heat transferred through the TGM.
The temperatures in a traditional radiator are maintained at approximately 80°-110° C. These temperatures have been established based on optimal engine performance and sufficient fan size. By dumping additional waste heat from a TGM system into the radiator coolant loop during startup, substantial reductions in fuel consumption and emissions can be achieved due to increased warm-up speeds for the engine and catalytic converter. Additional waste heat in the main radiator cooling system also has the benefit in cooler weather of faster time to passenger compartment warmup, as well as improvement in warmup time of other vehicle fluids, such as engine oil and other engine lubrication fluids. These are positive effects of using the traditional radiator coolant loop to maintain the cold-side of the TGM.
However, using the radiator as the cold side heat sink for the TGM limits the ability to reduce the cold-side temperature below 80 C without adversely affecting engine efficiency. Thus, in accordance with one aspect of the present invention, an intermediate or stand-alone cooling loop for the cold side of the TGM provides for possible reduction in the cold-side temperature. This permits an increase in the temperature differential across the TGM. Cooling for this intermediate cooling loop may be provided by an additional fan or a greater surface area heat sink. In one embodiment, the main chassis of the vehicle could provide a large heat sink.
In another embodiment, the intermediate loop is coupled or in thermal communication with the main coolant radiator during startup, and decoupled for the remainder of operation. This would permit the faster warm-up times, yet permit maximizing the beneficial effects of the cold-side cooling system of the TGM. The embodiment described below incorporates these features.
FIG. 1 schematically illustrates one embodiment of a thermoelectric generation system 100 in the context of using waste heat from an engine or any other heat source as the thermal power source for the thermoelectric generator module. The thermoelectric generation system 100 has a thermoelectric generator module (TGM) 101 , an auxiliary cooler, which can be any air-liquid heat exchanger known in the art, such as an auxiliary radiator 104 , an auxiliary cold-side working fluid loop 118 , an auxiliary pump or other device that controls fluid flow known in the art 121 , an auxiliary cold-side working (heat transfer) fluid 114 , a bypass 120 , and a hot side working fluid 107 , such as exhaust, superheated steam, or any heat source. The hot side working fluid 107 may also be an auxiliary heat transfer fluid in a separate hot side heat transfer loop, where the heat was obtained from the exhaust. This auxiliary heat transfer fluid will be discussed further relating to FIG. 3 . The auxiliary cold-side heat transfer fluid 114 can be a liquid or molten salt such as liquid metal or NaK. It can also be a heat transfer fluid such as ethylene glycol/water or those made by Dow or other advantageous heat transfer fluids known in the art. It can also be superheated or saturated steam or another type of two-phase fluid. The auxiliary cold-side heat transfer fluid 114 can also be a gas like helium, hydrogen, air, or carbon dioxide or any other high heat transfer gas that can be operated at above atmospheric pressure in order to reduce pumping losses. The TGM 101 includes hot and cold side heat exchangers, TE elements, and electrical connectors between TE elements (not shown), preferably incorporating thermal isolation in the direction of working fluid flow, as described in U.S. Pat. No. 6,539,729, entitled Efficiency Thermoelectrics Utilizing Thermal Isolation, which patent is hereby incorporated by reference herein The TE elements in the TGM 304 can be thermally isolated advanced high power density designs or can be made of standard thermoelectric modules known in the art.
The thermoelectric generation system 100 is coupled at the cold side via a heat exchanger (hex) 109 to a the cooling system for an engine or any other heat source 102 having a main radiator 103 , a first bypass 105 , a second bypass 119 , a thermostat or valve or other fluid control mechanism known in the art 106 , a radiator valve or other fluid control mechanism known in the art 112 , main coolant 113 , and a main pump 108 . This connection to the cooling system of the engine 102 is optional. By providing the interconnection, faster warm-up times can be achieved for the engine, passenger compartment, and the like, during engine warm up. It will then be appreciated that the intermediate cold-side working fluid loop 118 may be completely uncoupled from the engine cooling system, and provide benefits of the present invention of an intermediate cold-side heat transfer loop, not limited by the operating restrictions on the coolant system for the engine.
A controller 150 monitors and controls operation. A number of sensors are advantageously strategically placed to monitor the system. These sensors are preferably temperature and/or flow sensors. The controller then communicates with control mechanisms such as the pumps 108 , 121 and valves 110 , 112 . The particular connections shown are merely exemplary, and sensors and control connections are provided as appropriate for the system design.
During steady state operation, main coolant 113 is circulated through the main coolant loop 117 using main pump 108 . The main coolant 113 is returned to the engine 102 after it has gone through the main radiator 103 and been cooled by the airflow 116 , which can be ram or fan air, flowing across the main radiator 103 in a typical cross-flow heat exchanger. This is standard operation for a vehicle cooling system. During vehicle startup, it is also standard for the thermostat 106 to prevent main cold flow 113 through the main radiator 103 , directing it through the bypass 105 and back to the engine 102 . This allows the main coolant 113 , and thus the engine 102 , to warm up faster. Engines are designed to run at higher efficiencies once they are warm. In addition, the catalytic converter in the exhaust system of the vehicle, which helps reduce harmful emissions, does not start being effective until its internal temperature reaches a specific “light off” temperature for its internal catalysts. Thus, it is possible to reduce emissions and increase vehicle fuel economy by warming up the engine faster.
The thermoelectric generator module (TGM) 101 is the component in the thermoelectric generation system 100 that generates electrical power from the waste heat of the vehicle. The TGM 101 can operate more efficiently if its cold-side temperature is kept as cold as possible. The main coolant 113 must operate between 80-110° C. to allow the engine to operate properly. This is the case no matter what the ambient temperature outside. The TGM 101 operates more effectively at a lower cold-side temperature than this. Thus, the TGM 101 is connected to the auxiliary cold-side heat transfer loop 118 using the auxiliary radiator 104 . The auxiliary heat transfer fluid 114 is pumped through the auxiliary radiator 104 and back to the TGM 101 with the auxiliary pump 121 . Airflow 115 , which can be ram or fan air, flows across the auxiliary radiator 104 , which may also be a cross-flow heat exchanger, removing heat from the auxiliary cold side working fluid 114 . The auxiliary coolant 114 is now independent from the main coolant 113 , and thus can be controlled by a separate pump and maintained at a temperature closer to ambient.
In one embodiment, to maximize performance throughout the drive cycle and take as much advantage of the waste heat as possible, the main coolant loop 117 and the auxiliary coolant loop 118 are connected with an optional heat exchanger 109 . During vehicle startup, valve 112 is open allowing main coolant 113 to flow through heat exchanger 109 . Valve 110 is also open allowing auxiliary coolant 114 to flow through heat exchanger 109 transferring waste heat from the TGM 101 stored in the auxiliary cold fluid 114 to the main coolant 113 . This allows the engine and catalytic converter to warm up faster providing the benefits described above. It will be understood that the heat exchanger 109 could simply interconnect the two cooling loops 117 , 118 , or could be a heat exchanger which facilitates heat transfer between the main coolant 113 and the auxiliary coolant 114 .
Once the engine 102 reaches operating temperature, and the catalytic converter (not shown) has reached “light off” temperature, sensors (not shown), which may exist in the main coolant loop 117 , intermediate coolant loop 118 , engine 102 , and the catalytic converter (not shown), communicate this information to controller 150 . Controller 150 then closes valves 110 and 112 preventing main coolant 113 and auxiliary heat transfer fluid 114 from going through heat exchanger 109 . In this embodiment, this effectively isolates the two systems. Controller 150 may also control pump speed for both auxiliary pump 121 and/or main pump 108 . Main coolant 113 circulates through bypass 119 and auxiliary cold fluid travels through bypass 120 . The main coolant loop 117 can operate at one temperature and the auxiliary heat transfer loop 118 can operate at another, preferably lower, temperature. Hot side fluid 107 flows through the TGM 101 to provide heat and higher temperature for the hot side of the TGM 101 .
As briefly mentioned above, the hot-side fluid 107 may be exhaust from the engine 102 , or may, in a preferred embodiment, be a separate hot-side heat transfer fluid, as will be explained further herein. Main pump 108 may be a similar or different device from that of auxiliary pump 121 . Similarly, main valve 112 may be similar or different to auxiliary valve 110 . Main radiator 103 may be similar or different from auxiliary radiator 104 . Main coolant fluid 113 may be similar or different from auxiliary coolant 114 .
FIG. 2 shows another embodiment for a thermoelectric generation system 200 , similar in many respects to that of the embodiment to FIG. 1 . An engine 102 , such as an engine in a car, provides a source of heat. The engine 102 has a cooling system using a radiator 103 . A separate intermediate cold side loop uses a heat dissipater 204 instead of the auxiliary radiator 104 and the airflow 115 is removed ( FIG. 1 ).
The heat dissipater 204 is representative of any other type of heat exchanger. For example, it could be the chassis of the vehicle. An auxiliary cold fluid 211 still flows through the heat dissipater 204 as did auxiliary cold-side working fluid 214 through the auxiliary radiator 104 ( FIG. 1 ). The heat transfer mechanism in this embodiment preferably is dominated by a large surface area and convection as opposed to a more compact heat transfer surface area and forced air convection as was presented with the auxiliary radiator 104 in FIG. 1 .
Hot Side Intermediate Loop
As with the cold-side intermediate loop, the present invention addresses the potential impedance mismatch for dynamic systems through an intermediate control loop for the hot-side of the TGM as well. In this embodiment, like the cold-side intermediate loop, the flow rate and temperature of the fluid can be adjusted to better match that needed to provide maximum power output and/or improved efficiency for a dynamic set of operating conditions. Thus, the power generator performs closer to optimal over a wider range of operating conditions.
The ability to control the flow rate in the intermediate loop controls the heat flux across the TE elements, where this is not possible in systems proposed in a conventional design. It also allows for more optimal thermodynamic cycles, such as thermal isolation in the direction of flow (as described in U.S. Pat. No. 6,539,729), to be implemented.
Thermal mass can also be provided in the intermediate loop sufficient to enable the power output of the generator system to be more constant over an entire dynamic cycle by storing heat energy during periods of high heat flux and releasing energy during periods of low heat flux. Controlling the pump speed can also aid in providing a more constant level of power. This ability to provide a constant thermal power level over a highly dynamic range of conditions can greatly simplify power conversion and controls for the generator system.
By incorporating the intermediate loop, the TE generator can also be isolated from the hot-side system, which is often operating under harsh conditions. This may be desirable in many instances, in particular where maintenance may be necessary on one system but it is undesirable to disturb the other system. For example, the intermediate loop allows the TE portion of the TE generator system to be contained within a separate hermetically sealed package. This can also allow for easier recycling of the TE material.
The intermediate loop also provides the ability to choose a better heat transfer fluid than the main heat source. If an intermediate loop fluid is chosen with better heat transfer characteristics than the primary hot fluid (e.g., engine exhaust), the thermoelectric generator module (TGM) can be built smaller. This compact size improves the ruggedness of the device and can enable it to fit applications where size, weight, and cost are critical.
The intermediate loop also permits the working fluid to be selected to be stable over the entire exposed temperature range. A working fluid having excellent heat transfer-related thermodynamic properties will minimize the amount of heat loss associated with the additional loop. Pump losses associated with moving the fluid through the control loop should be small in order to not offset the power generated by the TGM.
By having an intermediate loop, the possible array of working heat transfer fluids is greatly expanded. Liquid metals such as gallium and NaK have excellent thermodynamic properties and are stable liquids over a wide temperature range. As liquids, they also would help keep pumping losses at a minimum. However, they have very poor material compatibility with a variety of different materials, and, thus, are not necessarily good choices for this application. But, the existence of the intermediate loop provides the option to consider such fluids in the possible working fluids.
Other heat transfer liquids considered that are manufactured by such companies as Dow do not remain stable over certain temperatures. Even silicone liquids become unstable over 400° C.
For the present applications, the fluids that remain stable over wide temperature ranges are generally gases. Gases such as hydrogen and helium have excellent thermodynamic properties. Hydrogen, unfortunately, is a highly flammable fluid and can cause materials to become brittle, particularly at high temperature. Helium, however, is inert and, thus, has excellent material compatibility. It has excellent thermodynamic properties when compared to water. In some respects it has better thermodynamic properties than glycol solutions. Its main drawback is its density. Being a very light gas, at atmospheric pressure, pumping losses are high for helium. These pumping losses, however, can be minimized by increasing the fluid's working pressure as well as mixing the helium with a small amount of a heavier fluid. One such fluid is xenon, which is also an inert gas and is substantially heavier than helium. Xenon does not have good thermodynamic properties and may be more expensive than helium. Thus, in one embodiment, the amount of xenon used would be minimized.
There are other gas possibilities for the working fluid. These include CO 2 and air. Both of these gases are heavier than helium and, thus, do not require the addition of xenon, but they have worse thermodynamic properties.
FIG. 3 shows the first embodiment of the power generator system 300 with intermediate loop control 311 . A main hot fluid 301 , which could be vehicle exhaust gas, superheated steam, or any heat source, flows through the primary heat exchanger (PHX) 303 . The PHX 303 can be a shell and tube or any other heat exchanger type known in the art. If the temperature or mass flow rate of the main hot fluid 301 exceeds preset limits, a 3-way valve 308 or other flow directional device known in the art can be opened such that flow will be directed through the bypass 307 rather than through the PHX 303 .
Preferably, a control system monitors the temperature and a controller 350 for the central system and adjusts the valve 308 to the correct level so that the system operates as effectively as practical. This helps to protect the thermoelectric (TE) material in the thermoelectric generator module (TGM) 304 from being overheated. In the example of an engine, this can also be used to prevent excessive backpressure in the main hot-side loop 309 (e.g., in the exhaust), which in the case of a motor vehicle can adversely affect the performance of the vehicle's engine. Preferably, the bypass 307 routes the main hot fluid (some small portion to virtually all of the fluid) around the PHX 303 and back to the main hot-side loop 309 , when that improves performance or achieves some other desired result. The valve 308 thus allows partial flow to go through the bypass 307 and partial flow through the PHX 303 under the control of the controller 350 . Preferably, the controller 350 has sensors at for at least the hot fluid 301 , an intermediate loop fluid 302 and a cold-side working fluid 305 . In one embodiment, the controller sensors would detect at least temperature, and possibly flow rate for the fluids. Also, the controller 350 preferably provides control for the valve 308 and pump 306 , to control the flow rates and proportion the flow through valve properly.
In this embodiment, heat is transferred from the main hot fluid 301 to the intermediate loop hot-side working fluid 302 via the primary heat exchanger PHX 303 . In one embodiment, the intermediate loop hot-side working fluid 302 can be a liquid or molten salt such as liquid metal or NaK. It can also be a high temperature heat transfer fluid such as those made by Dow. The intermediate fluid 302 can be superheated or saturated steam or another type of two-phase fluid. The intermediate fluid 302 can also be a gas like helium, hydrogen, air, or carbon dioxide or any other high heat transfer gas that can be operated at above atmospheric pressure in order to reduce pumping losses.
A pump 306 or other device capable of controlling flow known in the art 306 can control the thermal mass flow or thermal impedance of the intermediate loop fluid 302 to “match” or equal that of the hot fluid 301 , if desired. This helps to maximize the effectiveness of the PHX 303 . This is particularly important for a system where the hot fluid 301 flow rate or temperature fluctuates over a wide range. Maximizing the effectiveness of the PHX 303 over the dynamic range of hot fluid flows improves TGM 304 and thus the entire generator system 300 over an entire cycle. Without this control, the system would only operate at optimal performance over a very narrow range of operating hot fluid 301 flows. The intermediate loop 309 also provides a level of thermal storage for the system. The thermal mass of the intermediate loop fluid 302 provides a means of thermal energy storage, which can be augmented by the pump 306 flow speed.
The intermediate loop heat transfer fluid 302 is circulated around the hot-side intermediate loop 311 and through the TGM 304 using the pump 306 . The TGM 304 preferably includes hot and cold side heat exchangers, TE elements, and electrical connectors between TE elements (not shown), preferably incorporating thermal isolation in the direction of working fluid flow, as described in U.S. Pat. No. 6,539,729, entitled Efficiency Thermoelectrics Utilizing Thermal Isolation. The TE elements in the TGM 304 can be thermally isolated advanced high power density designs or can be made of standard thermoelectric modules known in the art. Cold-side fluid 305 flows through the cold-side heat exchanger portion of the TGM 304 to complete the thermoelectric generator.
FIG. 4 illustrates a thermoelectric generation system 400 very similar to that of the system 300 of FIG. 3 . This thermoelectric generation system 400 includes an additional thermal storage 409 . Controller 350 preferably includes an added sensor for the thermal storage 409 . The sensor permits the controller 350 to calculate whether additional thermal storage capacity is available, and effectively use this storage in controlling the operation of the system 400 . This thermal storage 409 can be any type of media with thermal mass, including phase change material and the like. This thermal storage 409 enhances the thermal storage capacity of the intermediate loop 311 allowing the system 400 to produce useful power during periods of low temperatures and mass flows of the hot fluid 301 up to and including even when there is no hot fluid 301 flow. When there is no hot fluid flow, the system would then “borrow” heat from the thermal storage. Likewise, when there is an excess of thermal power above that which the system 400 is capable of utilizing efficiently, thermal power can be stored.
FIG. 5 shows a system 500 that is similar to that of the system 400 of FIG. 4 . The difference is that the thermal storage 509 is located in the hot-side loop 310 rather than the intermediate loop 311 . Again, the controller 350 preferably includes a sensor for the thermal storage 509 , to detect the temperature of the thermal storage 409 , under the control of controller 350 . The thermal storage 509 at this location in this embodiment is advantageous if there is space (volume), weight, or other considerations that would prevent the thermal storage from being located as it is in FIG. 4 .
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A thermoelectric power generator is disclosed for use to generate electrical power from heat, typically waste heat. An intermediate heat transfer loop forms a part of the system to permit added control and adjustability in the system. This allows the thermoelectric power generator to more effectively and efficiently generate power in the face of dynamically varying temperatures and heat flux conditions, such as where the heat source is the exhaust of an automobile, or any other heat source with dynamic temperature and heat flux conditions.
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FIELD OF THE INVENTION
[0001] This invention relates to scalable lossy compression of scanned documents. Its applications include intelligent document management system, electronic delivery and reproduction of documents through the Internet.
BACKGROUND OF THE INVENTION
[0002] This invention deals with the problem of lossy coding of scanned documents, i.e., scanned documents are compressed to a significantly reduced bit rate at the price of a degradation in quality. Current popular approaches, such as that described by L. Bottou et al., High quality document image compression using DjVu, Journal of Electronic Imaging, Vol.7, pp.410-425, July 1998, and R. L. de Queiroz et al., Optimizing block-thresholding segmentation for multiplayer compressing of compound images, IEEE Trans. on Image Processing, Vol.9, pp. 1461-1471, September 2000, both belong to the so-called Mixed Raster Content (MRC)-based approaches. They decompose a document into background, foreground and mask layers, and then compress each layer separately. The principle weakness with such layer-based approach is its intrinsic redundancy. Meantime, the rate control and the scalability feature are not efficiently handled in layer-based approaches.
[0003] U.S. Pat. No. 5,778,092, to MacLeod et al. granted Jul. 7, 1998, for Method and apparatus for compressing color or gray scale documents, describes a technique for compressing a color or gray scale pixel map representing a document.
[0004] A. Said and A. Drukarev, Simplified segmentation for compound image compression, Proceeding of ICIP 1999, discusses the relative advantages of object-based, layer-based and block-based segmentation schemes.
[0005] M. J. Weinberger, The LOCO-I lossless image compression algorithm: principles and standardization into JPEG-LS, IEEE Trans. on Image Processing, Vol.9, No.8, pp.1309-1324, August 2000, describes the LOw COmplexity LOssless COmpression for Images (LOCO-I) compression algorithm.
SUMMARY OF THE INVENTION
[0006] A method of compressing a document, includes preparing an encoded representation of a document by scanning the document to provide a scanner output; classifying the scanner output as belonging to a class of document taken from the document classes consisting of smooth, text, graphics and image; and adaptively compressing the scanner output as a function of the class of the document.
[0007] A compression apparatus for compressing scanned data, includes a scanner for scanning a document and generating a scanner output; a block-based classifier for classifying the scanner output as belonging to a class of documents taken from the document classes consisting of smooth, text, graphics and image; an adaptive compressor for compressing the scanner output according to a compression mode as a function of the class of document; a storage mechanism for storing compressed scanner output and compression mode information; and a decompressor for decompressing compressed scanner output in accordance with the compression mode information.
[0008] An object of the invention is to provide an efficient engine and method for compressing the data file of a scanned document.
[0009] Another object of the invention is to provide a compression technique which is a function of the type of subject matter contained in the scanned document.
[0010] This summary and objectives of the invention are provided to enable quick comprehension of the nature of the invention. A more thorough understanding of the invention may be obtained by reference to the following detailed description of the preferred embodiment of the invention in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1. The histogram of blocks belonging to different document classes: FIG. 1( a )—smooth; FIG. 1( b )—text; FIG. 1( c )—graphic; and FIG. 1( d )—image.
[0012] [0012]FIG. 2 depicts an original document to be scanned and compressed.
[0013] [0013]FIG. 3 depicts the classification map for the document of FIG. 2.
[0014] [0014]FIG. 4 depicts a comparison of an original text document (FIG. 4( a )), and decoded prints of the text after processing by the BCAC of the invention (FIG. 4( b )), by DjVu (FIG. 4( c )), and by JPEG2000 (FIG. 4( d )). JPEG 2000 may be found at http://www.jpeg.org/JPEG2000.htm.
[0015] [0015]FIG. 5 depicts a comparison of an original graphic document (FIG. 5( a )), and decoded prints of the text after processing by the BCAC of the invention (FIG. 5( b )), by DjVu (FIG. 5( c )), and by JPEG2000 (FIG. 5( d )).
[0016] [0016]FIG. 6 depicts a comparison of an original image document (FIG. 6( a )), and decoded prints of the text after processing by the BCAC of the invention (FIG. 6( b )), by DjVu (FIG. 6( c )), and by JPEG2000 (FIG. 6( d )).
[0017] [0017]FIG. 7( a ) depicts an original text region, and the decoded text region before post-processing (FIG. 7( b )), and after post-processing (FIG. 7(C)) by the BCAC of the invention.
[0018] [0018]FIG. 8 is a block diagram of the apparatus of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The Block-based Classification and Adaptive Compression (BCAC) coder of the invention provides a novel solution to the lossy compression of scanned documents. It structures the image into non-overlapping blocks and does the classification on a block-by-block basis. Depending on the classification results, the block is adaptively compressed using one of four different standard compression methods: singular mode, binary mode, M-ary mode and continuous mode. All of the generated symbols are coded by an adaptive binary arithmetic coder (QM-coder). The overall complexity is kept comparable to that of JPEG-2000. The BCAC coder and method of the invention include two stages: a block-based classification stage and an adaptive compression or coding stage, which are separately detailed as follows:
[0020] Block-based Classification
[0021] The classification is based on empirical statistics collected from the data within the block. FIG. 1 depicts several examples of typical histograms, showing pixel value on the x-axis and frequency count on the y-axis, of the blocks belonging to different classes: FIG. 1( a )—smooth class, e.g., having only one dominant value; FIG. 1( b )—text class, e.g., having two dominant values; FIG. 1( c )—graphic class, e.g. having more than two dominant values; and FIG. 1( d )—image class, e.g. having no dominant values. Depending on whether there is only one or no dominant value in the distribution, the smooth blocks (FIG. 1( a )) and the image blocks (FIG. 1( d )) may be identified. The distinction between a text block (FIG. 1( b )) and a graphics block (FIG. 1( c )) is subtle because the anti-aliasing effect found around the text regions may introduce a false mode detection. One way to overcome such difficulty is to exploit the contrast information. A block is classified as a text block only if its contrast is larger than a preselected contrast threshold, Th. Meanwhile, to facilitate the following coding stage, the classification method of the invention enforces the following order of priority to the classification: smooth>text>graphics>image. Such selection of ordering priority is the result of observations that compressing a block in a dominant value with a higher priority than warranted seriously affects the visual quality of the block upon decompression. For example, when a graphics block is coded in binary mode, one or more colors may disappear.
[0022] Based on the above discussion, a sequential classification scheme is used. The classification is summarized into the following sequential three steps:
[0023] 1) The histogram function, f(c), and the max/min values within a B×B block are obtained. If the difference between max and min is below a preselected threshold, e.g., 8, the block is classified as a smooth block. A pixel value c is said to be dominant if f(c)>f(c+1) and f(c)>f(−1) and f(c)>th 1 =0.1, where th 1 is the threshold for determining a dominant value.
[0024] 2) Otherwise, the first two dominant values c 1 , c 2 are found and the cumulative probability, p (summation over [c 1 −A, c 1 +A] and [c 2 −A, c 2 +A]) are calculated. If |c 1 −c 2 |>128 and p>Th, the block is classified as a text block.
[0025] 3) Otherwise, all valid dominant values are found and the cumulative probability is calculated. If the number of dominant values n belongs to [1, M] and the cumulative probability p (summation over all [c k −A, c k +A] for k=1, . . . , n)>th 2 , where th 2 is the threshold used to distinguish graphic block from image blocks, the block is classified as a graphics block. Otherwise, the block is classified as an image block.
[0026] [0026]FIG. 2 depicts the original test image used to acquire experimental data. The classification results, B=32, A=M=4, and th 1 =0.10 and th 2 =0.75, are seen to be reasonably satisfactory. The classification result for each block is explicitly transmitted to the decoder. Therefore the classification is only performed at the encoder. Such asymmetric structure is desired in many real applications, e.g., browsing scanned documents over the Internet using a rather simple docoder.
[0027] Adaptive Compression and Coding
[0028] Based on the classification result, the block is compressed in one of the following four modes: singular mode, binary mode, M-ary mode and continuous mode.
[0029] Singular mode. The compression of a smooth block is simple. Only the mean value needs to be transmitted to the decoder. Spatial scalability is also straightforward.
[0030] Binary mode. The block is first quantized into a binary map and then a progressive JBIG-like coder is used to compress the binary map, JBIG, Progressive bi-level image compression, International Standard, ISO/IEC 11544, 1993. The values of c 1 , c 2 are transmitted to the decoder as the side information. It should be noted that some post-processing technique, e.g., the low-pass filter, described in Table 1, may be used to simulate the anti-aliasing effect at the decoder. A simulation example is provided later herein to demonstrate the visual effect of low-pass filtering on decoded text blocks.
0 ⅛ 0 ⅛ ½ ⅛ 0 ⅛ 0
Table 1: Low-pass Filter Simulating the Anti-aliasing Effect
[0031] Though the low-pass filter intentionally “blurs” the sharp edge around the text regions, the mean-square error (MSE) value compared to the original image is significantly reduced. The text blocks are also visually closer to the original ones after the postprocessing.
[0032] M-ary mode. The coding in this mode is similar to the compression of a palette-based image. Since only a small palette (M=4) is allowed, a direct context-based entropy coding scheme is suitable. If the nearest two causal neighbors are considered, there are 4 2 =16 different contexts in total. Spatial scalability is a more challenging problem in this mode. Classical linear transforms, such as wavelet transforms, fail to preserve level-set and thus do not lead to efficient coding of palette-based images. The approach of extending the famous lifting scheme of W. Sweldens, The Lifting Scheme: A new philosophy in biorthogonal wavelet constructions, Wavelet Applications in Signal and Image Processing III, pp. 68-79, Proc. SPIE 2569, 1995, is used to obtain a level-set preserving multi-resolution decomposition of the palette image. For simplicity, the low-resolution image is obtained directly from the downsampling of the high-resolution image, i.e., s(i, j)=x(2i, 2j). The image s(i, j) is used to predict the other three quarters of the image x(i, j):
x ^ ( 2 i , 2 j + 1 ) = s ( i , j ) , x ^ ( 2 i + 1 , 2 j ) = s ( i , j ) , x ^ ( 2 i + 1 , 2 j + 1 ) = P [ x ( 2 i , 2 j ) , x ( 2 i + 1 , j ) , x ( 2 i , 2 j + 1 ) ]
[0033] where P[·] is a modified median edge detection predictor, directly using x(2i, 2j) to predict x(2i+1, 2j+1) when no horizontal or vertical edge is detected. The prediction residue is generated by e=x−{circumflex over (x)}(mod M) and its reversibility is achieved by e=x+{circumflex over (x)}(mod M). Empirical studies show that the overall bit rate increases by about 10% to 30% with the multi-resolution constraint
[0034] Continuous mode. Scalable compression of the image block has been extensively studied in recent years. Wavelet-based coders have demonstrated the very best compression performance while offering flexible scalability features. Here, the normalized S+P wavelet transform, described by A. Said and W. A. Pearlman, An image multiresolution representation for lossless and lossy image compression, IEEE Trans. on Image Processing, vol. 5, pp. 1303--1310, September 1993, is used for its computational efficiency. Because the transform works on a block-by-block basis, a symmetric extension technique is used at the block boundaries to alleviate potential block artifacts. Wavelet coefficients are scanned and coded in a bitplane-by-bitplane order. A two-stage coding technique, similar to the LZC coder proposed by Taubman et al., Multirate 3D subband coding of video, IEEE Trans. on Image Processing, Vol. 3, No. 5, pp. 572-588, September 1994, is employed. At the first stage (zero coding), the positions of significant coefficients are first transmitted by a JBIG-like coder, at the second stage (refinement coding), the magnitude of significant coefficients are coded after a binary expansion. In order to keep the overall computational complexity low, no rate-distortion optimization technique is used.
[0035] Results
[0036] Using the flower image of FIG. 2, with the size of 1728, or, as used in the actual experiment, 2016, because it contains abundant text/graphic blocks as well as image blocks, the BCAC coder of the invention is compared to the popular DjVu coder and the JPEG2000 VM8 coder. Though the JPEG2000 standard is not developed for compressing compound images, it may be used as a reference in the comparison. In the BCAC coder, all symbols are coded by an adaptive binary arithmetic coder. The overall computational complexity of the BCAC coder appears to be acceptable. For example, it takes around 5 seconds for JPEG2000 or BCAC coder to compress the flower image on a Pentium-III 866M machine, while DjVu requires in excess of 10 seconds. FIGS. 4 - 6 depicts the original and decoded text, graphic and image regions taken from the decoded image by three the different coders. The actual bytes used by BCAC, DjVu and JPEG2000 are 129234, 138312 and 130622, respectively, which correspond to the bit rate of about 0.3 bpp. The PSNR results achieved by BCAC, DjVu and JPEG2000 are 27.8 dB, 21.0 dB and 31.4 dB, respectively. Though JPEG2000 achieves the highest PSNR result, its subjective quality is not the best. Indeed PSNR values do not faithfully reflect the visual quality of a compound image especially for the text and graphics blocks. It is easy to observe that the BCAC coder achieves much better performance than DjVu and JPEG2000 coders in terms of subjective quality. Because the quality of text/graphics blocks are preserved by a handful of bits, more bits may be spent to code the image blocks and achieve better visual quality. In FIG. 7, the text blocks before and after post-processing are compared. The block after the low-pass filtering is seen to more accurately represents the original block. The PSNR improvement is about 2.3 dB.
[0037] The BCAC coder apparatus of the invention is depicted in FIG. 8, generally at 10 . A scanner 12 provides a scanner output in the form of a file containing the digital data generated from the document in question. A block-based classifier 14 includes histogram generator 16 and a threshold selection mechanism 18 . The threshold selection mechanism is most likely a manual input device, wherein a uses sets the various contrast threshold values. Classifier 14 provides an output which includes the scanner output and a flag to identify the class of document associated with the scanner output.
[0038] An adaptive compressor, or coder 20 , applies the proper compression mode to the scanner output, which mode is associated with the scanner output. The scanner output and the compression mode may be stored in a storage device 22 . The compressed scanner out put and the mode information is directed to a decompressor/decoder for processing to “revive” the document.
[0039] Though the coder of the method of the invention is designed for compressing scanned documents that contain significant noise, it is also applicable to the lousy compression of computer-generated documents that have little noise. Meanwhile, it is easy to generalize this scheme to compress color documents. Spatial scalability is an attractive feature provided by this approach. Reproduction of the scanned documents at various resolutions is useful in many important applications, e.g., intelligent document management systems can render scanned documents at the resolutions specified by the user.
[0040] Thus, a method and apparatus for compressing scanned documents has been disclosed. It will be appreciated that further variations and modifications thereof may be made within the scope of the invention as defined in the appended claims.
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A method of compressing a document, includes preparing an encoded representation of a document by scanning the document to provide a scanner output; classifying the scanner output as belonging to a class of document taken from the document classes consisting of smooth, text, graphics and image; and adaptively compressing the scanner output as a function of the class of the document. A compression apparatus for compressing scanned data, includes a scanner for scanning a document and generating a scanner output; a block-based classifier for classifying the scanner output as belonging to a class of documents taken from the document classes consisting of smooth, text, graphics and image; an adaptive compressor for compressing the scanner output according to a compression mode as a function of the class of document; a storage mechanism for storing compressed scanner output and compression mode information; and a decompressor for decompressing compressed scanner output in accordance with the compression mode information.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of and claims the benefit of previously filed, co-pending U.S. patent application Ser. No. 12/647,084, filed Dec. 24, 2009, by Enzo Dalmazzo, which claims benefit of provisional Application, Ser. No. 61/140,723, filed Dec. 24, 2008 by Enzo Dalmazzo, entitled Autonomous Wireless Antenna Sensor System, the disclosure of this application being incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of wireless communications, and more particularly, to the application of telemetry to improve the robustness of wireless communications infrastructures.
BACKGROUND OF THE INVENTION
[0003] An essential part of a wireless service provider's business is its ability to provide adequate communication capabilities to its customers. In order to provide such capabilities, wireless service providers deploy communication antennas on towers, rooftops, buildings, and other tall structures. The height of such structures allows the radio signal from each communication antenna to travel several miles, establishing a geographic area within which service may be provided to customers. Wireless service providers typically install several directional communication antennas per site as multiple directional communication antennas are needed for increased capacity and reception.
[0004] In order to provide the required radio signal throughout a defined area, each directional antenna is intended to face a specific direction (referred to as “azimuth”) relative to true north, to be inclined at a specific downward angle with respect to the horizontal in the plane of the azimuth (referred to as “downtilt”) and to be vertically aligned with respect to the horizontal (referred to as “skew”). Undesired changes in azimuth, downtilt, and skew will detrimentally affect the coverage of a directional antenna. These alignments may be likened to the axes commonly used to describe the attitude of an aircraft: Azimuth corresponds to the yaw of an aircraft about a vertical axis; skew corresponds to the roll of an aircraft about its longitudinal axis; and downtilt corresponds to the pitch of the nose of an aircraft above or below a horizontal plane (or about a lateral axis extending horizontally through the aircraft at right angles to the longitudinal axis). In general, the more accurate the installation, the better the network performance that may be achieved within the area served by the antenna. Directional antenna installations are performed by tower companies who use certified tower climbers to carryout such installations.
[0005] An antenna's azimuth, downtilt and/or skew can change over time, due to the presence of high winds, corrosion, poor initial installation, vibration, hurricanes, tornadoes, earthquakes, or other factors. It is common for wireless service providers to conduct periodic audits of their communication antennas to ensure that each antenna has not deviated significantly from its desired azimuth, downtilt and/or skew. Wireless service providers frequently hire third party tower companies to perform audits and to make any necessary adjustments to maintain the desired azimuth, downtilt and skew. Such audits, however, may be labor intensive and dangerous, frequently requiring certified tower climbers to physically inspect each antenna, and to take appropriate measurements to determine any deviance from the desired positioning. This task can become even more time consuming if many towers are affected as a result of a hurricane or storm, in which case it could take between two to four months to figure out which towers have been affected, as the antennas have to be checked one by one.
[0006] Given the present state of the art, there is a need in the art for means for remote and continuous monitoring to determine whether and to what extent the desired physical positioning of an antenna has been altered.
SUMMARY OF THE INVENTION
[0007] The present invention includes an autonomous wireless antenna sensor system that provides wireless service providers with an alternative to periodic audits or spot checks following events that may have changed an antenna's positioning. The autonomous wireless antenna sensor system of this invention measures physical changes in the azimuth, downtilt, or skew of a communication antenna. The system of the present invention may initiate an alert to a wireless service provider, for example, when it detects is a change in the azimuth, downtilt or skew of a communication antenna sufficient to require realignment of the antenna, or when it detects a tilt that is unacceptable.
[0008] The autonomous wireless antenna system of the present invention may include three subsystems: a wireless antenna sensor, a remote sensor control station, and a remote graphical user interface (“GUI”). The system may also include a repeater or relay device, used to retransmit sensor signals to the remote sensor control station. In one embodiment of the present invention, a wireless antenna sensor measures changes in antenna azimuth downtilt and skew by using a gyroscope microchip and an accelerometer microchip, or a combination of both. Information regarding changes in antenna alignment can be relayed from the wireless antenna sensor attached to the communication antenna to the remote sensor control station located near the wireless service provider's base station at the foot of an antenna tower, using any low power wireless communication medium, such as Zigbee IEEE 802.15.4, Bluetooth, or WiFi. If desired, a wired connection, such as one following AISG Standards, may also be used for this purpose.
[0009] It is an object of this invention to provide a method for remotely monitoring changes in the positioning of antennas mounted on towers or other difficult-to-access locations so that appropriate and timely corrections may be applied.
[0010] It is another object of the invention to provide a user interface that is remote from a number of antenna sites, whereby changes in the positions of one or more antennas may be detected, and appropriate remedial treatment may be applied.
[0011] It is a further object of the invention to provide electrical power to microchips on antennas without a requirement for running an electrical wire from a ground-based power grid to the antennas.
[0012] It is yet another object of the invention to provide a method for remotely measuring the degree of misalignment of an antenna so that appropriate corrective measures may be taken without the need to conduct full re-alignment procedures.
[0013] These and other objects of the invention will become apparent in the following descriptions of the drawings and of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic drawing illustrating an antenna tower and antennas used in an autonomous wireless antenna sensor system in accordance with at least one embodiment of the present invention;
[0015] FIG. 2 is a schematic drawing illustrating the mounting of wireless antenna sensors to antennas in accordance with one embodiment of the present invention;
[0016] FIG. 3 is a schematic drawing illustrating the components and communications media for an autonomous wireless antenna sensor system in accordance with one embodiment of the present invention; and
[0017] FIG. 4 is a schematic drawing illustrating a first method for obtaining antenna alignment information in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] The present invention together with the aforesaid objects and advantages is best understood from the following detailed description of the preferred embodiments of the invention. The autonomous wireless antenna system of the present invention may include three subsystems: a wireless antenna sensor, a remote sensor control station, and a remote graphical user interface (“GUI”). The system may also include a repeater or relay device, used to retransmit sensor signals to the remote sensor control station. In one embodiment of the present invention, a wireless antenna sensor measures changes in antenna azimuth downtilt and skew by using a gyroscope microchip and an accelerometer microchip, or a combination of both. In one embodiment of the present invention, a gyroscope microchip may be used to measure variations in azimuth, and an accelerometer microchip may be used to measure changes in downtilt and skew. In embodiments where such microchips feature high precision and sensitivity, signals from both sensors may be used as inputs to a processor whose output combines and processes the sensor information to provide a more accurate means for determining and measuring changes of an antenna's azimuth, downtilt, and skew. Variations in antenna alignment that can be false alarms may be reduced or eliminated though signal processing, for example, by cross referencing instantaneous accelerometer information against longer term gyroscopic information.
[0019] The remote sensor control station of the present station may relay antenna alignment data via a wired or wireless communications link. In this manner, the remote sensor control station can provide antenna alignment information to a remotely-located user viewing a graphical user interface. In one embodiment, software for monitoring and recording alignment information and changes provide a baseline for determining when sufficient misalignment has occurred to require a wireless service provider to take corrective action (e.g., by contracting an antenna maintenance company to properly align antenna).
[0020] In one embodiment of the present invention, the wireless antenna sensor and its wireless communications system may function with low power requirements which can be satisfied in any of a number of ways. For example, Radio Frequency (“RF”) energy may be harvested from the RF signal emitted by the antenna site itself to provide power to run the wireless antenna sensor and its wireless communication system. Alternatively, solar power, wind power, or piezo electric power (e.g., generated from mechanical stress as the tower is moved by the wind), coupled with a battery or storage capacitor, may produce power sufficient to run the system. If desired, electrical power from a base station may be provided through a new or existing electrical wire on the tower. The wired option, which may follow AISG Standards, may require additional electrical wire to be run up the tower.
[0021] As wireless antenna sensors used on the antennas may have unique electronic serial numbers, the system of this invention is not limited to only indicating when an antenna becomes misaligned, but may also specifically identify the antenna from which the measurements are taken. Wireless service providers can use the antenna identification information to accurately manage antenna assets. Thus, one of the advantages of the present invention is that maintenance or replacement can more easily and accurately be achieved than is currently possible through the haphazard antenna maintenance procedures currently used by most third party tower maintenance companies.
[0022] Once the components of the system of the present invention are installed, a wireless service provider would no longer need to hire third party tower companies to verify antenna azimuth, downtilt or skew through visual observation or manual field measurements. Use of the present invention allows sensing of antenna positioning as changes in the positioning occur, such as for example, a change in the attitude of the sensors attached to the antenna. The antenna position changes may be relayed to a remote sensor control station, and also the wireless service provider may be notified of any undesired changes via a Remote GUI, for example.
[0023] FIG. 1 illustrates two embodiments of the wireless antenna system of the invention. The wireless antenna system may be retrofitted on a tower 10 supporting multiple antennas 30 , 31 receiving and radiating electromagnetic energy in the RF range 40 . The antennas 30 , 31 may also radiate in other frequency bands.
[0024] FIG. 1 shows at the base of the tower 10 a base transceiver station 80 which may also house and electrically support a remote receiver control unit 20 . Cables 50 may conduct communication signals to and from antennas 30 , 31 , and may be part of the original antenna installation.
[0025] FIG. 2 illustrates another aspect of the invention where antennas 30 , 31 are attached to the antenna tower 10 , and include microchip sensors 60 , 61 , and 70 , 71 secured directly to the antennas. For each antenna, one microchip ( 70 , 71 ) may serve as an accelerometer to measure antenna movement in two directions, as along X and Y axes, such as tilt and skew, and a second microchip ( 60 , 61 ) may serve as a gyroscope to measure angular movement, such as variations in azimuth. In an alternative embodiment, a combination of signals from microchips attached to the antennas, when processed by a CPU, may also provide precise information regarding changes in antenna positioning without triggering false alarms.
[0026] FIG. 3 is a schematic depiction of the operation of the system in accordance with one embodiment of the present invention in which two antennas 30 , 31 are being monitored for movement away from a desired orientation. As is shown in FIG. 3 , movement sensors 60 , 61 , 70 , 71 generate signals that are fed to and transmitted by smaller antennas 150 , 151 to receiving antenna 110 at ground station 20 . In an alternative embodiment, the signals transmitted by antennas 150 and 151 are received by a repeater 21 ( FIG. 1 ) which in turn may retransmit these signals at the same or a different frequency to the antenna 110 . The repeater may be positioned anywhere within the coverage of the antennas 150 and 151 .
[0027] A sensor (e.g., 60 , 61 , 70 , or 71 ) may powered by one or more RF energy harvesting 90 and storage devices 100 located on the tower 10 in the vicinity of the antennas. In one embodiment, the wireless antenna sensors may be located within a housing to prevent moisture buildup. The sensors may be attached to the antenna using any conventional attachment method. Alternatively, industrial strength adhesive tape may be used for attaching the wireless antenna sensors to their respective communication antennas 30 , 31 .
[0028] The sensors and/or the wireless antennas may have a unique electronic serial numbers which may serve to identify a specific antenna or sensor. The wireless antenna sensors may transmit the measured antenna alignment information (e.g., change in azimuth, tilt or skew) to remote sensor control station 20 or the relay station 21 together with antenna or sensor identification information. In one embodiment, the wireless antenna sensor, through its corresponding antenna (e.g., 150 or 151 ), communicates over the air with remote sensor control station 20 via Zigbee IEEE 802.15.4 Wireless Standard or its equivalent.
[0029] The remote sensor control station 20 may be installed in or around the wireless service provider's base transceiver station 80 that is conventionally located on or near the ground level. In one embodiment of the present invention, at least one remote sensor control station 20 may be present at each site. A remote sensor control station may have a unique address, such as a MAC or IP address.
[0030] The remote sensor control station 20 may periodically request or receive measurement results from the wireless antenna sensors 60 , 61 , 70 , 71 . The intervals for which the measurements are taken may be user defined. Measurement records may be date and time stamped. The remote sensor control station may assign a user defined name to each wireless antenna sensor and data from the sensors may be processed and placed on a lookup table. An antenna name may reference a particular antenna being measured by each wireless antenna sensor. The remote sensor control station may be programmed to report only defined wireless antenna sensors in order to ensure that only the desired antenna(s) are being monitored. Measurement reports may be stored in the remote sensor control station's memory or on a hard storage device 120 . Once measurements are stored, they may be retrieved from the remote sensor control station either locally using a PC and a data cable (USB or other suitable connector) or remotely, such as via a Telco (i.e., T1) or mobile communication device/data card (such as, for example, GSM/CDMA/IDEN/SATELITE).
[0031] Information stored, and management functions of the autonomous wireless antenna sensor system, may be remotely controlled via a local area network (“LAN”) or Internet connection 130 by a remote user GUI 140 . The remote user GUI may be web based and may require a user name and password in order to access it. The remote user GUI can be hosted on either the Internet or the user's intranet. The remote user GUI's functions include retrieving the data from online remote sensor control stations and storing the data on a database which may be an online database. Once the data is imported, the user can upload the desired/target measurements for azimuth, tilt and skew which determine the specifications to which the antennas should adhere. The most recent measurement results may be displayed by date, time, site name, and antenna name. The user may request that the difference in measurement from a desired/target position for each antenna be provided in a report generated by the system. The user may also define the maximum difference measurement that will be allowed and request that the remote user GUI produce an alarm log that will display all out-of-specification antennas. The user may also require that the remote user GUI notify him or her, via e-mail or other communication means, of any out-of-specification antennas, at which time the user may reposition the specific antenna. By correcting the orientation of out-of-specification antennas as adverse conditions develop, needless testing and periodic third party audits may be avoided.
[0032] FIG. 4 illustrates a first method for obtaining antenna alignment information in accordance with one embodiment of the present invention. In this embodiment, the remote system 80 is active and remains in low power mode when no event occurs. An event may be defined as a change in antenna positioning that deviates from acceptable antenna specification. In step 401 the remote system 80 is powered and an application running in an end-user's computer, for example, is started. This application may be used in conjunction with the GUI 140 to interface with and control certain functions of the remote site 80 . In step 403 the end-user computer, which may also be referred herein as the remote system base, gathers data indicative of the status of the remote system 80 and optionally sends calibration commands to the remote station 80 .
[0033] In step 405 the remote station 80 determines whether an event has occurred. If no event is detected, the remote system 80 enters in a wait mode. After a time out period (which may be changed by the system operator) elapses, the remote system 80 captures data ( 409 ) provided by antenna sensors, which may include temperature, sensor battery level, and the antenna alignment information (e.g., yaw, pitch, or roll). In step 411 the captured data may be sent to the remote base system together with control data from the remote site 80 .
[0034] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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Systems and methods are enclosed for processing antenna position information. The systems and methods involve positioning at least one sensor in proximity to an antenna for measuring alignment of the antenna; at a ground station in proximity to a tower holding the antenna, periodically receiving antenna alignment information from the at least one sensor; and transmitting the alignment information to a control station for determination whether the alignment of the antenna complies with antenna specifications.
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REFERENCE TO COPENDING APPLICATION
This is a Continuation-In-Part application of Ser. No. 437,589, filed Jan. 29, 1974, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of forming microcapsule films in a polar liquid. In greater detail the present invention relates to a method of forming (modifying) microcapsule films using polyfunctional amines (including derivatives thereof). The microcapsule films obtained by the method of the present invention have low porosity, are not water permeable, have low light transmission, are difficulty swelled by water or moisture, and are thick and strong.
2. Description of the Prior Art
Hitherto, many methods for encapsulating hydrophilic materials in a polar liquid are known.
The microcapsules function to change the apparent state and property of the materials, to protect the materials in a very fine state, to control the discharging ability and to discharge the contents thereof at an appropriate time.
The functions of the microcapsules are as follows:
A. IT IS POSSIBLE TO CHANGE A LIQUID MATERIAL INTO AN APPARENTLY SOLID MATERIAL,
B. IT IS POSSIBLE TO MODIFY THE WEIGHT AND QUANTITY OF MATERIALS,
C. IT IS POSSIBLE TO CONTROL THE DISCHARGING OF THE MATERIALS CONTAINED IN THE CAPSULES,
D. IT IS POSSIBLE TO ISOLATE REACTIVE MATERIALS AND THUS TWO OR MORE REACTIVE MATERIALS CAN BE CONTAINED AT THE SAME TIME IN THE SAME SYSTEM FOR A LONG PERIOD OF TIME OR MATERIALS INCLUDED CAN BE PROTECTED FROM EXTERNAL INFLUENCES OR STORED FOR A DESIRED PERIOD OF TIME,
E. IT IS POSSIBLE TO SHIELD THE COLOR, THE FLAVOR AND THE VIRULENCE OF THE MATERIALS CONTAINED, AND
F. THEY HAVE THE PROPERTIES OF A FINELY DIVIDED POWDER.
Much research has been conducted to apply these functions to recording materials, medical supplies, perfumes, agricultural chemicals, chemicals, adhesives, liquid crystal paints, foods, detergents, dyestuffs, solvents, catalysts, enzymes and rust inhibitors, etc. Pressure sensitive copying sheets, aspirin capsules, perfume containing capsules, menthol containing capsules, pressure sensitive capsule adhesives, rust inhibitor containing capsules used for riveting, liquid crystal containing capsules and insecticide containing capsules have been practically used.
The methods of encapsulating can be classified into chemical processes, physico-chemical processes and physico-mechanical processes. Further, combinations of these processes can be utilized.
Methods of producing microcapsules are illustrated in the following in greater detail.
As the methods for microencapsulating utilizing chemical processes, an interfacial polymerization process and an "in situ" polymerization process are known.
Microencapsulation using the interfacial polymerization process utilizes a reaction for synthesizing polymers. The interfacial polymerization process is reported in Journal of Polymer Science, 60, 299 (1950).
In this process, an interfacial polymerization reaction is utilized using a combination of a hydrophobic monomer (or a prepolymer thereof) and a hydrophilic monomer (or a prepolymer thereof). Namely, the hydrophobic monomer is added to an organic medium which has no affinity to water, and the solution is finely dispersed in an aqueous phase. Then a water soluble or water dispersible monomer is added to the aqueous phase, by which the polymerization reaction occurs at the water and oil interfaces to form polymer films. Compounds used for such film formation are polyfunctional materials which cause a polycondensation reaction or an addition polymerization reaction. Thus, the formed capsules have a polyamide, polyester, polyurethane or polyurea film.
A number of patents concern encapsulation utilizing this principle, as disclosed, for example in Japanese Pat. Publication Nos. 19574/63, 446/67, 771/67, 2882/67, 2883/67, 8693/67, 8923/67, 9654/67 and 11344/67, and British Pat. Specification Nos. 950,443, 1,046,409 and 1,091,141. In these methods, the rate of supplying the monomers becomes low in forming the capsule film and the supplying thereof finally stops. Consequently, the resulting microcapsules generally have a thin capsule film which is a typical semipermeable membrane. In the "in situ" polymerization process, film forming materials are supplied to either the inside or the outside of the drops of the core material, and consequently polymerization occurs at the surface of the drops of the core material. Since most known polymerization reactions can be utilized, many kinds of capsule films can be formed.
A number of patents concern methods in which an oily monomer and core materials coexist, for example as described in Japanese Pat. Publication No. 9168/61, British Pat. Specification No. 1,237,498, French Pat. No. 2,060,818, and 2,090,862. Methods for producing a polymer film on the surface of core material by applying a film forming material from the dispersion medium are described in British Pat. Specification No. 989,264, Japanese Pat. Publication No. 14327/62 and 12380/62.
In the capsule films produced by these methods, film formation is not sufficiently carried out in general, and, consequently, the porosity of the capsule films is comparatively high.
Methods for microencapsulating utilizing a physical process, include a phase separation method using an aqueous solution and a drying method comprising drying in a liquid.
The phase separation methods using an aqueous solution comprise separating a thick polymer phase from an aqueous solution of a water soluble polymer. These methods have been practically utilized for many purposes at present. Such methods include a complex coacervation process and a simple coacervation process.
The method utilizing complex coacervation are described in U.S. Pat. Nos. 2,800,457, 3,116,206, 3,687,865, 3,265,630 (Japanese Pat. Publication No. 7726/62), 3,190,837 (Japanese Pat. Publication No. 7724/62), and 3,041,289. As methods for hardening capsule films formed, methods are described in Japanese Pat. Publication No. 3878/62, 3876/62, 3877/62, 12376/62, 24782/62, and U.S. Pat. No. 3,401,123, wherein formaldehyde, glutaraldehyde and glyoxal are used as a hardening agent.
The capsule films formed by these methods have substantially poor resistance to water or moisture and undergo swelling or permit permeation of the contents, because they are produced from water soluble polymer starting materials. Further, low molecular weight materials can pass through capsule films formed because the films per se are porous. Furthermore, the contents (the encapsulated materials) can be extracted by alcohols, ethers or ketone solvents. Methods utilizing simple coacervation are described in U.S. Pat. No. 2,800,458, French Pat. No. 1,304,891, Japanese Pat. Publication No. 7727/62, 7731/62 and 9681/62.
The capsule films formed by these methods have the same properties as the capsule films produced by complex coacervation.
The drying method comprising carrying out drying in a liquid comprises dispersing a solution of a capsule film forming material containing core materials in a encapsulating medium and volatilizing the solvent to form rigid capsule films.
This method has been described in Japanese Pat. Publication Nos. 13703/67, 28744/64 and 28745/64.
The capsule films formed by this method are usually a thin semipermeable membrane. Accordingly, they have the disadvantage that low molecular weight core materials penetrate through the capsule film.
Typical methods for producing capsules and the characteristics of the capsule films formed have been described above. But, additionally, phase separation methods using an organic solvent (e.g., the methods described in Japanese Pat. Publication No. 12379/62 and U.S. Pat. No. 3,173,878) and drying methods comprising drying in a liquid (e.g., the methods described in Japanese Pat. Specification No. 28744/64 and 28755/64) are known, but they are not satisfactory because of the thickness and density of the capsule films.
An object of the present invention is to eliminate the technical problems of the above described numerous encapsulation methods and to provide a method of forming capsule films having improved "protective ability for the encapsulated materials" which is an ideal characteristic for "microcapsules".
Herein, the term "improvement of protective ability" means that the density of the formed capsule film is increased, that the permeability to water and resistance to light is reduced, that the degree of swelling by water or moisture is decreased and that the strength is increased.
SUMMARY OF THE INVENTION
The objects of the present invention can be attained using a method for forming microcapsule films having low porosity which comprises chemically or ionically binding a water soluble or water dispersable heterocyclic amine to a microcapsule film forming material, or depositing the heterocyclic amine solely or a water insoluble material formed by reaction with the heterocyclic amine onto the microcapsule films.
DETAILED DESCRIPTION OF THE INVENTION
The term heterocyclic amine as used in the present invention also includes derivatives thereof. Preferred examples of suitable heterocyclic amines are symmetric or asymmetric spiroacetal heterocyclic diamines.
Examples of the preferred spiroacetal heterocyclic diamines are represented by the following formula: ##STR1## wherein R 1 and R 1 ' each represents a hydrogen atom or a lower alkyl group (for example, a methyl group, an ethyl group and a propyl group) and R 2 and R 2 ' each represents a linear or branched chain alkylene group having 1 to 7 carbon atoms. Examples of suitable alkylene groups are methylene, ethylene, propylene, iso-propylene, butylene, pentylene, hexylene and heptylene groups. Preferred alkylene groups are straight chain groups.
Preferred examples of derivatives of the above compound include (1) the condensation products produced by reacting the amino groups of a diamine represented by the above formula with a compound containing at least one oxirane group, (2) the addition products produced by reacting the above amine with acrylonitrile, (3) the reaction products produced by reacting the above amine with urea, thiourea or guanidine, and (4) the reaction products produced by reacting the above amine with an alkylene oxide such as ethylene oxide, propylene oxide, octylene oxide, etc.
Specific examples of spiroacetal diamines represented by the above formula include 3,9-bis-(2'-aminomethyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(2'-aminoethyl)-2,4,8,10-tetraoxaspiro-(5,5) -undecane; 3,9-diethyl-3,9-bis-(2'-aminoethyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(3'-aminopropyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(2'-aminopropyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(4'-aminobutyl)-2,4,8,10-tetraoxasprio-(5,5)-undecane; 3,9-bis-(5'-aminopentyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis(1',1'-dimethyl-4'-aminobutyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(5'-aminopentyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane; 3,9-bis-(6'-aminohexyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane and 3,9-(7'-aminoheptyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane.
These compounds can be easily prepared according to processes described in, for example, German Pat. No. 1,092,029 and U.S. Pat. No. 2,996,517.
The compounds having an oxirane group which are a constituent of the derivatives include alkyl glycidyl ethers such as propyl glycidyl ether, butyl glycidyl ether and allyl glycidyl ether; condensates of epichlorohydrin and bisphenol (e.g. Epikote 562, Epikote 812, Epikote 815, Epikote 820, Epikote 828 and Epikote 834 trade names, produced by the Shell International Chemical Co.); phenol type epoxides prepared by reacting epichlorohydrin with a precondensate of a phenol resin; polyglycol type epoxides prepared by reacting a polyglycol such as ethylene glycol, propylene glycol and glycerol with epichlorohydrin; glycidyl esters in which the hydrogen of the carboxyl group is substituted with a glycidyl group (for example, "Kardula E" trade name, produced by the Shell International Chemical Co.); ethylene oxide, propylene oxide, octylene oxide and epoxypolybutadiene; epoxidized vegetable oil fatty acids prepared by reacting a glyceride of an unsaturated fatty acid with peracetic acid; and epoxy glycerides.
The condensation products of a compound having oxirane groups and the above described spiroacetal type diamine can be prepared according to well known methods by mixing and heating these materials in the presence or absence of a solvent to a temperature above the melting point of the spiroacetal diamine. Preferred condensates can be prepared by reaction in a system containing a spiroacetal diamine having one or more amino groups per oxiran group. The detail of this process are described in Example 1 of Japanese Pat. Publication No. 26097/68.
The addition products of the heterocyclic amine and acrylonitrile of the present invention can be easily produced according to known methods by heating these materials at a temperature above the melting point of the spiroacetal diamine component or near the boiling point of acrylonitrile in the presence or absence of a solvent. The details are described in Example 1 of Japanese Pat. Publication No. 2586/69. Further, the reaction products of heterocyclic amines and urea, thiourea or guanidine can also be easily produced using known methods.
The method of forming microcapsule films of the present invention can be applied to any microencapsulation process.
The heterocyclic amines used in the present invention are added to the system during a step for producing capsules or after formation of capsule films. However, in these processes it is preferred to add the heterocyclic amines as follows.
1. Interfacial Polymerization Process
It is preferred to add the heterocyclic amines during or after a dispersion step in the process comprising emulsification→dispersion→hardening→conclusion of encapsulation.
2. Coacervation Process
It is preferred to add during or after the cooling step which comprises cooling at a temperature below the gelling point of an ionizable hydrophilic colloid (particularly, gelatin) in the process comprising emulsification→coacervation→cooling→pre-hardening treatment→hardening→conclusion of encapsulation, and particularly at the pre-hardening treatment step. The pre-hardening treatment step means the step prior to that step in which the hardening agent is added and an alkali are copresent in the same system.
In the complex coacervation process to which this invention is applicable, the first step is an emulsification step in which a water-immiscible oil is emulsified in an aqueous solution of at least one hydrophilic colloid ionizable in water (the first sol) and then admixing an aqueous solution of a hydrophilic colloid (the second sol) having an electric charge opposite to that of the first sol. The temperature of emulsification and droplet formation is not important but must be no less than gelation point of gelatin, preferably about 40° C. The size of the droplets formed in this step is not critical and the % by weight of the hydrophilic colloid can be freely selected because the hydrophilic colloid solution is subsequently diluted with water added in the coacervation step to be discussed hereinafter. The time of admixing the first sol and the second sol can also be freely varied. As another embodiment, a water-immiscible oil can be emulsified in an aqueous solution of hydrophilic colloids which are ionizable in water and at least one of which is positively charged. The ratio of the hydrophilic colloids employed can be varied, but it is preferred that the ratio by weight of one hydrophilic colloid (on a solids basis) to the second hydrophilic colloid of opposite charge thereto be about 1.
In the next step, water is either added to the emulsified mixture or the pH is adjusted to cause coacervation. The amount of water to be added is that which will cause coacervation and the amount to be added can be easily selected by one of ordinary skill in the art, for example, based on the disclosure contained in U.S. Pat. No. 2,800,457. Again, the temperature of the system is not limiting but should not be lower than the gelation point of the gelatin. It is, however, preferred that the temperature of the system remain substantially constant until coacervation has been achieved. Where pH adjustment is used, the initial pH of the system and the pH change are not limiting but the final pH of the system must be no greater than the isoelectric point of gelatin, preferably from a pH of 7 to 2, for example, about 4. Suitable pH adjusting agents can be organic acids (e.g., succinic acid, acetic acid, etc.) and mineral acids (e.g., hydrochloric acid, etc.).
In step 3, the coacervates are cooled to cause gellation. The temperature at the beginning of the cooling step is substantially the same as that used in the coacervation step. The temperature at the completion of the cooling step should be no greater than gelation point of the gelatin and generally is no lower than the freezing point of water (e.g., until about 5° C), usually at about 10° C.
The rate of cooling is not important and will depend on the volume to be cooled. Rapid cooling can be utilized in accomplishing the gellation step.
Once the coacervates have gelled, the pH of the system is adjusted to the alkaline side. A preferred pH after adjustment is from a pH of about 7.5 to about 12. Usually the final pH will be about 10. The temperature during pH adjustment to the alkaline side is not critical but thus temperature should be no greater than the gelation point of the gelatin. The pH can be rendered alkaline utilizing agents such as NaOH, KOH and the like. A hardening agent can be added after adjusting the pH to the alkali side. Both a hardening agent and an alkali can be also added at the same time.
The above steps can be followed where desired by a hardening step in which the temperature of the coacervate is optionally raised to more effectively harden the coacervate. The temperature is, for example, about 40° C to 60° C.
As the hydrophilic colloids, there are included natural or synthetic ones such as amino acid containing compounds, for example, gelatin, casein, alginate, and the like, saccharides, such as gum arabic, carrageenan, copolymers such as styrenemaleic anhydride copolymers, methyl vinyl ether-maleic anhydride copolymers, and the like, cellulose compounds, such as carboxymethyl cellulose, cellulose sulfate and the like, soluble starches such as sulfated starch, etc.
As the hydrophobic materials for the nucleus of the individual microcapsules, there are illustrated natural mineral oils, animal oils, vegetable oils, synthetic oils, and the like. Examples of the mineral oils include petroleum and petroleum fractions such as kerosene, gasoline, naphtha, and paraffin oil. Examples of the animal oils include fish oils, lard oil and the like. Examples of the vegetable oils include peanut oil, linseed oil, soybean oil, castor oil, corn oil and the like. Examples of synthetic oils include biphenyl derivatives such as alkylated biphenyls (e.g., methyl, ethyl, or isopropyl-substituted biphenyls), phosphate esters, naphthalene derivatives, phthalic acid derivatives, salicyclic acid derivatives and the like.
In order to emulsify and disperse a hydrophobic liquid which is to be the nuclear material in water, an anionic, cationic or non-ionic surface active agent is preferably used to prevent phase reversal (i.e., formation of a w/o emulsion). Turkey red oil or sodium alkyl benzene sulfonates can be utilized. An oil-in-water emulsion can be obtained by emulsifying a hydrophobic oily liquid which is converted to the nuclear material in at least one hydrophilic colloid aqueous solution, the colloid becoming a wall material. The resulting emulsion is then subjected to water dilution and adjustment of pH to thereby deposit the coacervate around the emulsified individual oil droplets. The coacervate deposited on the surface of the oil droplets is cooled from outside the vessel to gell the wall film. Then, in order to harden the wall film, formaldehyde, a dialdehyde, e.g., glutaraldehyde, or glyoxal; a ketoaldehyde, e.g., methylglyoxal; or a combination of formaldehyde and a dialdehyde or a ketoaldehyde; or an oxidation product of a polysaccharide is added to the system followed by adjusting the pH of the system to the alkali side, or else, the pH of the system is adjusted to the alkali side followed by adding the hardening agent thereto. The stage of adding formaldehyde is not particularly limited and may be before, during or after the above-described hardening procedure. The same effects of the combined use of the formaldehyde with a dialdehyde or a ketoaldehyde are obtained in any case.
In order to provide the capsule wall film with heat resistance, the system is left for a long period of time for example, a day, at a low temperature for example, room temperature, or, if short time processing is required, heated to about 40° to 60° C.
An encapsulation process utilizing coacervation has the defect that the hardening pretreatment step takes a long time. It is beneficial to use the procedure of British pat. specification No. 1,253,113 in coacervation, which improves the above defect and in the present invention because it becomes possible to convert the pH to the alkaline side in a short time in a hardening pretreatment by adding "a shock-preventing agent" in the presence of the hardening aldehydes.
The term "shock" as used herein means the phenomenon in which, in carrying out the hardening pretreatment of a coacervation capsule solution containing gelatin as described in the aforesaid British Patent specification, the viscosity is rapidly increased when the pH of the system is around the isoelectric point of gelatin. The term "shock-preventing agent" means a solution which prevents such shock. Shock-preventing agents which can be used in this invention are polyelectrolytes having an anionic functional group. As examples of such polyelectrolytes there may be mentioned modified cellulose, an anionic starch derivative, an anionic acid polysaccharide, a condensate of naphthalene sulfonic acid and formaldehyde, a hydroxyethyl cellulose derivative, a copolymer of vinylbenzene sulfonate, a copolymer of sodium acrylate and a copolymer of maleic acid anhydride.
As examples of modified cellulose, there may be mentioned polysaccharides having β-1,4-glucoside bonds of glucose and having anionic functional groups. Part or all of the hydroxyl groups of the cellulose may be etherified or esterified. Illustrative of cellulose ethers are carboxymethyl cellulose, carboxyethyl cellulose and metal salts thereof, and illustrative of cellulose esters are cellulose sulfate, cellulose phosphate and metal salts thereof.
The anionic starch derivative may be one which is composed of a linear polysaccharide amylose formed by only α-1,4 bonds of D-glucose, and a branched polysaccharide amylopectin formed by mainly α-1,4 bonds of D-glucose and partially side chain branched by α-1,6 bonds.
As examples of the above starch derivatives may be mentioned carboxymethyl starch, carboxyethyl starch, starch sulfate, starch phosphate and starch xanthate. These are obtained by etherification or esterification of corn starch, wheat starch, rice starch, potato starch, sweet potato starch or tapioca starch, which may be extracted from either the seeds or the roots of the plants in high yield.
As examples of the anionic acidic polysaccharides, there may be mentioned polygalacturonic acid, which is obtained by polycondensing linearly D-galacturonic acid between α-1,4 bonds thereof. The acid polysaccharide contains pectin, pectic acid and pectinic acid. These are basic substances comprising pectin matter in a high plane and have been defined as follows: pectinic acid-olygalacturonic acid in the colloid form containing some methyl ester groups pectin-water soluble pectinic acid containing methyl ester groups pectic acid-ollygalacturonic acid in the colloid form containing no methyl ester groups.
The separation of these compounds may be conducted, in general, by extraction from acids.
The condensate of naphthalene sulfonic acid and formaldehyde is represented by the following formula: ##STR2## wherein X is a hydrogen atom, an alkali metal or an ammonium group, and n is a positive integer.
Shock-preventing ability of the above condensate is influenced by the degree of polymerization, and it is preferable that n be 5 to 9. In general, the larger the value of n, the more the water-solubility and viscosity increases. These compounds are described in Kogyo Kagaku Zashi, 66 [1], pp. 55-69 (1963).
As examples of the hydroxyethyl cellulose derivatives, there may be mentioned carboxymethyl ether of hydroxyethyl cellulose, hydroxyethyl cellulose sulfate and hydroxyethyl cellulose phosphate and the like.
As examples of the copolymers of vinylbenzene sulfonate, there may be mentioned vinylbenzene sulfonate-acryloylmorpholine copolymer, vinylbenzene sulfonate-morpholinomethylacrylamide copolymer, vinylbenzene sulfonate acrylamide copolymer, vinylbenzene sulfonate-vinylpyrrolidone copolymer, and vinylbenzene sulfonate-methoxymethylacrylamide.
These polymers contain the following group in the molecule: ##STR3## wherein M is an alkali metal and n is a positive integer. The amount of vinylbenzene sulfonate in the copolymer is preferably 45-95 mol percent, more preferably 60-85 mole percent, and it is preferred, for the purpose of this invention, to use a copolymer having a molecular weight of 10,000 to 3,000,000, particularly 100,000 to 1,000,000.
As examples of copolymers of acrylic acid, there may be mentioned acrylic acid-acryloylmorpholine copolymer, acrylic acid-morpholinomethylacrylamide, acrylic acid-acrylamide copolymer, acrylic acid-vinylpyrrolidone copolymer, and acrylic acid-methoxymethylacrylamide.
These polymers contain the following group: ##STR4## wherein X is a hydrogen atom or an alkali metal, and n is a positive integer.
The amount of acrylic acid in the copolymer is preferably in 40 to 95 mol percent, especially 50 to 85 mol percent, and it is preferable, for the purpose of this invention, to use a copolymer having molecular weight of 6,000 to 2,000,000, especially 50,000 to 1,000,000.
As examples of copolymers of maleic acid anhydride, there may be mentioned a copolymer of maleic acid anhydride and an unsaturated compound having an active double bond (e.g. styrene, ethylene, methylvinyl ether, vinylacetate) salts thereof (e.g. alkali metal salts such as Na and K, ammonium salts) and half esters thereof (e.g. alkyl esters such as methyl esters and ethyl ester).
The amount of the polyelectrolyte is from 1/12 to 1/2 by weight based on the total amount of hydrophilic colloids present.
As has been stated above, the process of the present invention is extremely useful for the production of microcapsules. It is useful to combine the present invention and those processes as described in OLS (Offenlegungsschrift) Nos. 2,133,052 and 2,138,842 or U.S. Ser. No. 354,050/73, now U.S. Pat. No. 3,970,585. It is also useful to combine the present invention and those processes relating to the addition of a coacervate-inducing agent at a step prior to the completion of gelation of the coacervate, as described in, for example, OLS Nos. 2,120,922; OLS 2,135,68; OLS 2,210,367.
3. "In situ" Polymerization Process
It is preferred to add the heterocyclic amine during or after a dispersion step in the process comprising emulsification→dispersion→hardening→conclusion of encapsulation.
4. Other Capsulation Processes
It is preferred to add the heterocyclic amine during or after a dispersion step.
In the present invention, the heterocyclic amines can be used alone or they can be used together with water-soluble compounds which form water insoluble materials upon reaction with the heterocyclic amines, such as aldehydes, and epoxy compounds (they can be added separately or at the same time to the system).
The above described compounds are added in an amount of about 1/100 to about 10 times and particularly about 1/10 to about 2 times by weight of the heterocyclic amines used.
In the practice of the present invention, more dense capsule films can be formed if water soluble or water dispersable amines having at least one amino group in addition to the above described heterocyclic amines, such as octyl amine, nonyl amine, dodecyl amine, stearyl amine, ethylene diamine, trimethylene diamine, 1,7-diaminoheptane, 1,9-diaminononane, 1,10-diaminodecane, N,N'-diaminopropyl piperazine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, m-hexamethylene triamine, tris-(N-aminopropyl) isocyanurate, guanidine and trimethylolmelamine, are used together with the above described heterocyclic amines in the amount below about 70% and particularly below 50% (by weight) thereof. The above described amines can be added separately or simultaneously with the addition of the heterocyclic amines.
Many of the spiroacetal diamines of the present invention have the properties that under alkaline conditions cloudiness results and they easily react with the above described compounds such as aldehydes resulting in precipitation in water. Further, they are stable themselves and do not color during storage. Accordingly, they are very easy to treat.
These properties remarkably increase the effects of the present invention.
Furthermore, it is preferred to change the pH of the system into a more alkaline range by adding an alkali such as sodium hydroxide, potassium hydroxide and sodium carbonate after adding the heterocyclic amines and/or other additives and to heat to a temperature above room temperature (about 18° C).
In any encapsulating process, the addition of the heterocyclic amines of the present invention should be carried out under agitation.
The aldehydes which are one of the preferred additives include acetaldehyde, formaldehyde, glyoxal, methylglyoxal, glutaraldehyde, acrolein, 2-hydroxyadipaldehyde and dialdehydostarch. By use of these aldehydes, the present invention can be more effectively carried out.
The aldehydes can be added before or after addition of the heterocyclic amines. Of course, they can be added simultaneously with addition of the heterocyclic amines.
In the practice of the present invention, the quantity of the heterocyclic amines is not limited. Because, the effect caused by the compound increases depending on the quantity thereof, and thus the quantity thereof is determined on the basis of the characteristics desired. It is preferred that the amount of the amines be within a range of from 1/1000 to 1/2, more preferably 1/100 to 1/5, weight ratio based on the core (nucleus) material. Especially, it is effective to modify the capsule films formed from gelatin. Namely, surprising effects, for example, an improvement in light transmittance, a prevention of swelling by moisture, an improvement in strength and an increase in density can be obtained.
In the prior method for producing capsules using aldehydes as a hardening agent, unreacted aldehydes generally remain and cause stimulative odor. According to the present invention, these residual isolated aldehydes effectively disappear and, consequently, capsules do not have a bad odor.
Moreover, it is a very important fact in the present invention that the capsules neither coalesce nor aggregate even though the capsule films are remarkably modified.
The synthesis of the heterocyclic amines of the present invention are illustrated in greater detail in the following synthesis examples. Unless otherwise indicated, all parts, percents, ratios and the like in all of the examples given hereinafter are by weight.
SYNTHESIS 1
6.8g (0.05 mols) of pentaerythritol, 1g of p-toluene sulfonic acid and 100ml of toluene were mixed with 18.5g (0.1 mols) of 5-cyanopentanal dimethylacetal. The mixture was refluxed by heating for 4 hours. The reaction mixture was filtered and the filtrate was condensed under vacuum to produce 17.9g of 3,9-bis-(4'-cyanobutyl)-2,4,8,10-tetraoxaspiro (5,5) undecane as a viscous liquid.
This viscous liquid was dissolved in 60 ml of ethanol and charged into an autoclave together with 100 ml of ethanol saturated with ammonia and 5 g of an activated (alkali-treated) Raney cobalt catalyst. Hydrogen was added at an initial hydrogen pressure of 107 kg/cm 2 at a reaction temperature of 120° C for 2 hours. After separating the catalyst by filtration, the filtrate was condensed and the condensate was distilled under vacuum to produce 8.2 g of 3,9-bis-(5'-aminopentyl)-2,4,8,10-tetraoxaspiro (5,5)undecane as a distillate having a boiling point range of 217°-221° C/0.2 mmHg.
33.1 Parts by weight of the resulting 3,9-bis-(5'-aminopentyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane were melted by heating. Then 13.0 parts by weight of butyl glycidyl ether were added dropwise with stirring while keeping the temperature at 60° C. After addition, the mixture was stirred for an additional 2 hours. The resulting reaction condensate was a colorless transparent viscous liquid.
SYNTHESIS 2
13.6 g of 3,9-bis-(6'-cyanohexyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane was produced by condensing 11.9 g of 7-cyanoheptanal dimethyl acetal with 43.5 g of pentaerythritol. Then this was catalytically reduced as described in Synthesis 1 to produce 8.6 g of 3,9-bis-(7'-aminoheptyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane. Melting point: 74°-75° C.
386 Parts by weight of the thus resulting 3,9-bis-(7'-aminoheptyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane were melted at 80°-85° C, and 130 parts by weight of butyl glycidyl ether were added dropwise thereto over a 1.5 hour period with stirring. After addition, the mixture was stirred for an additional 2 hours to produce colorless transparent viscous liquids.
SYNTHESIS 3
109.6 g (0.4 mols) of 3,9-bis-(3'-aminopropyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane (hereinafter, ATU) was melted in a reactor equipped with a sitrrer, a reflux condenser, an addition funnel and a thermometer while keeping the temperature at 45°-55° C. Then 30.0 g of phenyl glycidyl ether was added dropwise over a 2 hour period with stirring. After addition, the mixture was stirred for an additional 2 hours.
The resulted reaction mixture was a colorless transparent viscous liquid.
SYNTHESIS 4
27.4 g (0.1 mols) of ATU and 11.4 g (0.1 mols) of allyl glycidyl ether were subjected to reacting under the same conditions as described in Synthesis 3 to produce.
SYNTHESIS 5
27.4 g (0.1 mols) of ATU and 6.5 g (0.05 mols) of butylglycidyl ether were subjected to reacting under the same conditions as described in Synthesis 3 to produce.
SYNTHESIS 6
27.4 g (0.1 mols) of ATU and 9.3 g (0.05 mols) of E Kardula (trade name, glycidylester produced by the Shell International Chemical Co.) were subjected to reacting in the same manner as described in Synthesis 3.
SYNTHESIS 7
274 g (1 mol) of 3,9-bis-(3'-aminopropyl)-2,4,8,10-tetraoxaspiro-(5,5)-undecane was melted with keeping the temperature at 45°-55° C. Then, 53 g (1 mol) of acrylonitrile was added dropwise over a 1 hour period with stirring. After the addition, stirring was continued at 60° C for an additional 1 hour to stoichiometrically produce a colorless transparent viscous liquid.
The present invention will be illustrated in greater detail by several examples. The following examples demonstrate the characteristics of the present invention. However, these examples are not to be construed as limiting the scope of the present invention.
EXAMPLE 1
6 Parts of acid treated gelatin (from pigskin) having an isoelectric point of 8.2 and 6 parts of gum arabic were dissolved in 30 parts of water at 40° C. To this solution, 0.2 parts of sodium nonylbenzene sulfonate were added as an emulsifier.
30 Parts of diisopropylnaphthalene containing 2.5% (by weight) of Crystal Violet lactone (CVL) and 2.0% (by weight) of benzoyl leuco Methylene Blue as a color forming oil were added to the colloid solution with vigorous stirring to produce an oil/water (O/W) emulsion. Stirring was stopped when the oil drop size became 6 - 10μ.
To this emulsion, 200 parts of warm water at 40° C were added. 20% hydrochloric acid was added dropwise while stirring to adjust the pH to 4.4. The mixture was cooled externally with stirring to gel the colloid films deposited on the oil drops. When the liquid temperature became 10° C, 2.0 parts of a 37% formaldehyde solution were added while stirring. Then 20 parts of a 7% solution of sodium carboxymethyl cellulose having an etherification degree of 0.75 were added thereto.
A solution prepared by diluting 2.0 parts of the compound of Synthesis 1 with 5 parts of water was added dropwise thereto. Then a 10% solution of sodium hydroxide was added dropwise thereto to adjust the pH to 10. The mixture was kept at 40° C for 1 hour by external warming to obtain color former oil containing capsules.
The capsules obtained by this example were useful for producing a pressure-sensitive copying paper. For example, 10 parts of a 10% solution of PVA-210 (a polyvinyl alcohol, average degree of polymerization 1000, degree of saponification -- 87%, produced by Kuraray Co.) and 3 parts of corn starch were added to 100 parts of the resulting capsule slurry. The mixture was applied in an dry amount of 5.5 g/m 2 to a sheet of paper having a weight of 50 g/m 2 and dried to produce a coated paper. On the other hand, a mixture prepared by adding 7 parts of a 10% solution of PVA-210 and 3 parts of corn starch to 100 parts of capsules which were produced without using the compound of Synthesis 1 was applied in a dry amount of 5.5 g/m 2 to a sheet of paper a weight of 50 g/m 2 and dried to produce a copying paper (Comparison 1). When the characteristics of these coating paper were compared, the results shown in Table 1 were obtained.
From the results set forth in Table 1, it can be seen that the strength, permeability of the capsule films and the moisture resistance were remarkably improved.
Table 1______________________________________ Capsules of Capsules of Example 1 Comparison 1Properties of Capsule Films D D______________________________________Strength of Capsule Film Pressure Resistance 0.12 0.15 Friction Resistance 0.08 0.12 Moisture Resistance 0.30 0.40Permeability of Capsule Film1 0.25 0.852 0.06 0.283 0.08 0.24Light Stability (light permeability)1. Coloring after Exposure Exposure 10 Minutes 0.10 0.1230 Minutes 0.15 0.222. Activity of Color Former Exposure 0 Minute 0.95 0.9410 Minutes 0.92 0.9030 Minutes 0.87 0.8160 Minutes 0.82 0.68______________________________________
Excepting for the item "Activity of Color Former", the smaller the color density D is, the more preferable the result is.
Method of Testing
Developer Sheet Used: Method of Producing Developer Sheet A:
100 parts of activated acid clay which was treated with sulfuric acid were dispersed in 300 parts of water containing 6 parts of a 40% aqueous solution of sodium hydroxide and 0.5 parts of sodium hexametaphosphate using a Kedy mill. To this dispersion, 4 parts of Alon 20LL (trade name: a sodium polyacrylate produced by the Toa Gosei Chemical Industry Co.) were added. Then, 35 parts of Dowlatex 636 (trade name: styrenebutadiene latex produced by the Dow Chemical Co.) were added thereto.
This solution was applied to a sheet of paper having a weight of 50 g/m 2 by knife coating so as to provide a solids content of 8.0 g/m 2 . Further, in order to increase the surface smoothness the coated paper was treated by a super-calender to produce a sheet having a surface smoothness of 120 seconds (measured using a Beck smoothness tester).
Method of Producing Developer Sheet B:
5 parts of acid clay and 3 parts of aglomatolite were dispersed in 30.6 parts of water. The pH of this clay slurry was adjusted to 10 by adding 20% by weight of sodium hydroxide.
To this slurry, 0.1 parts of sodium hexametaphosphate and 0.2 parts of the sodium salt of a naphthalene sulfonic acid-form-aldehyde condensate (degree of polymerization -- 5, molar ration 1:1) were added. Then 5 parts of a 10% aqueous solution of gelatin having a gelatin strength of 56 g and an isoelectric point of 7.7 were added thereto with stirring. After slowly adding a solution of 0.7 parts of zinc chloride in 10 parts of water while stirring, a solution containing 2.5 parts of 3,5-di-tert-butylsalicylic acid and 0.4 parts of sodium hydroxide was slowly added thereto. Then 5 parts of Dow latex 636 (trade name: styrene-butadiene latex produced by Dow Chemical Co.) were added to produce a coating solution.
This coating solution was applied in an amount of 3 g/m 2 (dry basis) to a sheet of paper having a weight of 50 g/m 2 and dried to produce a coated paper.
This coated paper was treated using a super calender to produce a sheet having a smoothness of 125 seconds (measured using a Beck smoothness tester).
Method of Examination
Pressure Resistance: Developer Sheet A was used.
After putting the capsule sheet on the developer sheet so as to face the surface of the capsules to the surface of the developer and pressing for 30 seconds using a pressure of 40 kg/cm 2 , the color density on the surface of the developer sheet was measured using a reflection type spectrophotometer (wave length of measurement: 605μ).
Friction Resistance: Developer Sheet A was used.
After putting the capsule sheet on the developer sheet so as to face the surface of the capsules to the surface of the developer and moving the capsule paper by revolving the capsule paper under pressure (pressure: 20 g/cm 2 , rate of revolution: 30 r.p.m., line speed 1 m/min), the color density of the mark developed on the clay paper was measured using the spectrophotometer described above.
Moisture Resistance: Developer Sheet A was used.
The capsule sheet was put on the developer sheet so as to face the surface of capsules to the surface of the developer sheet and pressed using a pressure of 200 g/cm 2 . After leaving them in an atmosphere of RH 100% at 50° C, the color density of stains on the developer sheet was measured using the spectrophotometer described above.
Permeability of Capsule film:
1. The Developer Sheet B was put on the capsule sheet in the presence of water so as to face the surface of capsules to the developer sheet and dried at room temperature. Then the developed color density on the capsule sheet was measured using the spectrophotometer described above.
2. The Developer Sheet A was put on the capsule sheet in the presence of water so as to face the surface of capsules to the developer sheet and dried at room temperature. Then the developed density on the capsule sheet was measured using the spectrophotometer described above.
3. A developer slurry A was applied to the surface of the capsule sheet. After drying, the fog density was measured using the spectrophotometer described above.
Light Stability:
1. Coloring after Exposure:
After exposing the surface of the capsule sheet to sunlight, the color density of the sheet was measured using the spectrophotometer described above.
2. Activity of Color Former:
After exposing the surface of the capsule sheet to sunlight, the sheet was put so as to face to Developer Sheet A. Then, 600 kg/cm 2 of pressure was applied thereto to rupture the capsules, by which the content thereof transferred to the surface of the developer sheet. Then, the color density of the developed image was measured using the spectrophotometer described above.
The larger the density of the developed image is, the less the activity of the color former in the capsules decreases.
EXAMPLE 2
6 Parts of acid treated gelatin (from cattle hide) having an isoelectric point of 9.2 were dissolved in 25 parts of water at 40° C. 45 Parts of a color former oil having the following composition were added to this solution by pouring continuously. The mixture was agitated to produce an o/w emulsion containing emulsified drops having a drop size of 10 to 12μ.
______________________________________Composition of the Color Former Oil:______________________________________Crystal Violet Lactone 0.25 parts3-Methyl-2,2'-spiro-bi-(benzo(f) chromene) 0.5 parts7-N,N-Diethylamino-3-(N,N-diethylamino)- fluoran 7.5 partsRhodamine B-(p-nitroanilino)-lactam 0.5 parts7-Diethylamino-2,3-dimethylfluoran 2.5 partsBenzoyl Leuco Methylene Blue 2.0 partsMonoisopropylbiphenyl 70 partsCrocin 16 parts______________________________________
Then the emulsion was dispersed in 150 parts of warm water at 40° C with stirring. The encapsulation step described in the following was carred out with effective agitation. To this dispersion, 35 parts of a 10% solution of gum arabic and 10 parts of a 5% aqueous solution of the sodium salt of a styrene-maleic anhydride copolymer (Scripset 500 . . . trade name: produced by the Monsanto Chemical Co.) were added. Then 10 wt% of citric acid was added dropwise thereto to adjust the pH to 4.50.
Then the mixture was cooled externally to accelerate the formation of the capsule films and the gelling thereof. After cooling to 8° C, 0.5 parts of 40% glyoxal and 0.5 parts of 37% formaldehyde were added thereto. After mixing for 2 minutes, 1 part of a 20 wt% aqueous solution of polyacrylic acid, 6 parts of a 20 wt% aqueous solution of a condensate of sodium methylnaphthalene sulfonate and formaldehyde (degree of polymerization 5; molar ratio -- 1:1) and 12 parts of a 10 wt% aqueous solution of carboxymethyl starch (degree of etherification: 0.5) were added as a mixture.
Further, 20 parts of a 20 wt% aqueous dispersion of the compound of Synthesis 2 were added dropwise. After the addition, a 30% aqueous solution of potassium hydroxide was added thereto to adjust the pH to 9.5. The temperature of the solution was elevated to 40° C by heating externally. This temperature was kept for 30 minutes to produce color former containing capsules.
The resulting capsules were useful for producing a pressure sensitive paper. For example, 10 parts of a 20 wt% aqueous solution of acetyl starch (degree of acetylization -- 0.4), 1 part of a wheat starch powder having an average particle size of 18μ and 4 parts of Avicel (commercial name: microcrystalline cellulose, produced by the Asahi Chemical Industry Co.) were added to 100 parts of the produced capsule slurry, and the resulting mixture was applied to a paper having a weight of 50 g/m 2 so as to be 5.5 g/m 2 (dry basis) and dried.
This coating paper yielded a black color image with Developer Sheet A. Further, the above described additives were added in the same amounts as those described above to capsules produced without using the compound of Synthesis 2, and the resulted mixture was applied to paper a weight of 50 g/m 2 so as to be 5.5 g/m 2 (dry basis) and dried to produce a coating paper (Comparison -- 2).
The properties of both papers are shown in Table 2. It can be seen from the results contained in this table that capsules having improved strength, decreased permeability of capsule films and improved resistance are produced according to the method of this invention.
Table 2______________________________________ Example 2 Comparison 2Properties of Capsule Films D D______________________________________Strength of Capsule Film Pressure Resistance 0.10 0.14 Friction Resistance 0.07 0.10 Moisture Resistance 0.27 0.38Permeability of Capsule Film2 0.08 0.253 0.08 0.26______________________________________
EXAMPLE 3
To 30 parts of the diphenylmethane oil ##STR5## in which 2.5% (by weight) of Crystal Violet Lactone, 2.0% (by weight) OF Benzoyl Leuco Methylene Blue and 0.5% (by weight) of Rhodamin B-anilinolactam were dissolved as the color former for a pressure-sensitive recording paper, 6 parts of Colonate HL (commercial name: hexamethylene diisocyanatetrimethylolpropane addition product having residual isocyanate groups, molar ration -- 1:3 produced by Nippon Polyurethane Industry Co.), 2 parts of Actokol 51-530 (commercial name; polyoxypropylene polyol, produced by Takeda Chemical Co.) and 0.05 parts of dibutyl tin laurate were added and dissolved therein. The resulting oily solution was added to 50 parts of an aqueous solution containing 2 parts of carboxymethyl cellulose (approximate molecular weight -- 300; degree of etherification -- 0.75) and 2 parts of polyvinyl alcohol (saponification degree: 87%, average degree of polymerization: about 500) at 20° C with stirring.
To this mixture, a solution of 1 part of 3,9-bis-(3'-aminopropyl)-2,4,8,10-tetraoxaspiro(5,5)undecane, 5 parts of the compound of Synthesis 3 and 10 parts of water was added. Further, 2 parts of a 20 wt% NaOH solution were added thereto. During the above described treatment, the temperature of the system was kept less than 20° C. Furthermore, 2 parts of 37% formaldehyde were added thereto. In order to accelerate the reaction, the temperature of the system was increased to 70° C. This temperature was kept for 30 minutes to produce color former containing capsules having a firm capsule film.
On the other hand, the capsules which were prepared without adding 3,9-bis-(3'-aminopropyl)-2,4,8,10-tetraoxaspiro-(5,5)undecane, the compound of Synthesis 5 and formaldehyde in this example were used for the purposes of comparison (Comparison 3). The results of the comparative examinations are shown in Table 3.
To each capsule solution prepared in the above described manner, 6 parts of wheat starch having a particle size of 15μ and 40 parts of a 10 wt% solution of oxidized starch were added. The mixtures were applied to a paper having a weight of 50 g/m 2 so as to be 5.0 g/m 2 (dry basis) and dried.
Table 3______________________________________ Example 3 Comparison 3Properties of Capsule Films D D______________________________________Strength of Capsule Film Pressure Resistance 0.08 0.15 Friction Resistance 0.06 0.14 Moisture Resistance 0.10 0.25Permeability of Capsule Film1 0.14 0.362 0.06 0.153 0.05 0.18Heat Resistance of Capsule Film 100% 85%______________________________________
Heat Resistance Test for the Capsule Film
The thermal strength of the capsule coated paper was calculated using the following equation.
D.sub.1 /D.sub.2 × 100 = Heat resistance
wherein D 1 is the color density of the developed developer sheet which results on heating the capsule coated paper at 90° C for 10 hours, facing the surface of the capsule coating paper to the surface of the developer sheet and applying a pressure of 600 kg/cm 2 rupture the capsules. D 2 is the color density of the developed developer sheet which results on facing the surface of the unheated capsule coated paper to the surface of the developer sheet and applying a pressure of 600 kg/cm 2 rupture the capsules.
EXAMPLE 4
A color former oil was produced by mixing the following materials.
______________________________________Santotherm 66 (hydrogenated terphenyl, produced by Mitsubishi-Monsanto Co.) 30 partsCrystal Violet Lactone 0.5 parts3-Methyl-2,2'-spirobi-(benzo(f) chromene) 0.5 partsBenzoyl Leuco Methylene Blue 0.5 partsKerosine 5 parts______________________________________
5 Parts of polymethyl methacrylate and 1 part of Colonate L (commercial name; tolulenediisocyanate-trimethylolpropane addition product, produced by Nippon Polyurethane Industry Co.) were dissolved in 15 parts of methylene chloride. To this solution, the above described color former oil was added. (the temperature was kept to 16°-18° C.) (hereinafter designated (W -- oil)).
The (W -- oil) was emulsified in an aqueous solution of 4 parts of gum arabic, 2 parts of polyvinyl alcohol (PVA-210 above described) and 30 parts of water using a homogenizer having a high shearing force to produce an o/w emulsion having an average dropsize of 15μ. The temperature during emulsification was kept at 18°-20° C. The emulsion was then added in 100 parts of water.
To the resulted solution, 3 parts of the compound of Synthesis 4 and 25 parts of a 10% aqueous solution of dialdehyde starch were added, and further 5 parts of a 20% aqueous solution of hexamethylenediamine was added thereto.
The temperature of the solution was increased to 70° C by heating externally with stirring. This temperature was kept for 1 hour to conclude the encapsulation.
The resulting capsules had a heat resistance of 95% and good strength. They were useful for producing a pressure-sensitive copying paper.
EXAMPLE 5
25 Parts of dibutylmaleate were emulsified in an aqueous solution of 5 parts of polyvinylalcohol (average degree of polymerization: about 1000, saponification degree: 97%), 5 parts of the sodium salt of carboxymethyl cellulose (as described in Example 3) and 45 parts of water to produce and o/w emulsion having an average dropsize of 15 to 20μ.
The above resulting emulsion was added to 100 parts of water at 30° C. 20 parts of 35 wt% zirconium ammonium carbonate and 5 parts of 50 wt% urea were then added thereto with stirring. The temperature was increased to 50° C. The mixture was kept at this temperature for 1 hour, and then it was cooled to 25° C. Then 3 parts of the compound of Synthesis 4, 5 parts of a 50 wt% aqueous solution of tetraethylenepentamine, 1 part of adipic acid and 2 parts of a 37 wt% aqueous solution of formaldehyde were added thereto. The temperature was increased again to 65° C. The mixture was kept at this temperature for 1 hour to conclude the encapsulation.
The resulting capsules were spray dried to produce a dibutylmaleate containing capsule powder.
EXAMPLE 6
A perfume oil was prepared from 10 parts of orange perfume and 15 parts of trioctyltrimellitate.
This perfume oil was emulsified in an aqueous solution of 2 parts of the sodium salt of carboxymethyl cellulose (as described in Example 3), 3 parts of gum arabic and 30 parts of water to produce an o/w emulsion having an average drop size of 20 to 30μ. 100 Parts of water at 20° C were added with stirring. Then 20 parts of U-Ramin P-1800 (trade name; a cation type modified urea resin, produced by Mitsui Toatsu Chemicals Inc.), 2 parts of the compound of Synthesis 6, 10 parts of a 10 wt% guanidine sulfate and 2 parts of 37 wt% formaldehyde were added thereto.
Further, 20 wt% potassium hydroxide was added dropwise thereto to adjust the pH to 11.
The temperature was gradually increased to 60° C by heating externally while stirring slowly. The mixture was kept at this temperature for 24 hours.
To the resulting orange perfume capsule solution, 30 parts of a 20 wt% aqueous solution of polyvinyl alcohol (saponification degree: 87%, average degree of polymerization: about 1000) and 7 parts of corn starch were added to make a perfume ink. A paper support was printed with this ink using silk screen process. When the printed parts were rubbed with a finger, they gave out an intense orange scent.
Furthermore, when the capsules were broken by pressing the printed surface after the printed paper support was hung on a wall for a week, they gave out an orange scent. Thus, it can be seen that the capsules produced by the method of the present invention have an excellent perfume preservability.
EXAMPLE 7
7.5 Parts of Epikote 834 (trade name; an epoxy resin, produced by Shell Chemical Co.) were dissolved in 20 parts of toluene. An aqueous solution of 1 part of polyvinyl alcohol (average degree of polymerization: 1000; saponification degree: 87%), 3 parts of carboxymethyl cellulose approximate molecular weight: 300; degree of etherification: 075 and 25 parts of water was emulsified in the above toluene solution to produce an o/w emulsion having an average drop size of 10 to 15μ. To this emulsion, 50 parts of water at 20° C were added and then 2 parts of diethylaminopropylamine, 2 parts of the compound of Synthesis 7 and 1 part of 37 wt% formaldehyde were added thereto. To the mixture, 10 wt% sodium hydroxide was added to adjust the pH to 10.0. The temperature of the solution was increased to 60° C. The mixture was kept at this temperature for 24 hours while stirring.
As the result of carrying out the heat resistance test at 50° C for 24 hours, toluene did not decrease in the resulting toluene containing capsules.
EXAMPLE 8
6 Parts of acid treated gelatin (from whale) having an isoelectric point of 8.8, 4 parts of gum arabic and 0.5 parts of carboxymethyl starch (degree of etherification: 0.4, raw material: potato starch) were dissolved in 30 parts of water at 40° C. A liquid crystal composition consisting of 3 parts of methoxybenzylidene-p-n-butylaniline, 5 parts of cholesteryl chloride, 30 parts of cholesteryl nonylate and 4 parts of cholesteryl cinnamate was emulsified in the above solution to produce an o/w emulsion having an average drop size of 6 to 25μ. To the resulting emulsion, 175 parts of water at 35° C were added, and then 1 part of a phenol resin (a resorcinol modified phenol-formaldehyde resin, resin content: 60%) was added thereto. Further, a 10 wt% aqueous solution of adipic acid was added dropwise thereto to adjust the pH to 4.45. It was cooled to 8° C externally to accelerate the deposition of the colloid and the gelling thereof with the stirring being continued.
15 Parts of a 10 wt% solution of the sodium salt of carboxymethyl cellulose (degree of etherification: 0.78) were added thereto. After 1 part of 25 wt% glyoxal and 0.5 parts of 37 wt% formaldehyde were added, the pH of the mixture was adjusted to 10.0 by adding 10 wt% sodium hydroxide.
To the mixture, 3 parts of a 50 wt% aqueous dispersion of the compound of Synthesis 2 were added. The temperature of the mixture was increased to 40° C to produce a liquid crystal containing compound.
To this liquid, 4 parts of corn starch (average particle size: 15 to 20μ), 4 parts of wheat starch (average particle size: 25 to 35μ) and 10 parts of a SBR latex (styrene-butadiene rubber) were added.
A biaxial stretched polystyrene film support was treated using corona discharging to give a contact angle of about 60° C. Then the above described capsule solution was applied thereto and dried.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A method of forming low porosity microcapsule films which comprises chemically or ionically binding a water soluble or water dispersible heterocyclic amine to a microcapsule film forming material, or depositing the heterocyclic amine alone or a water insoluble material formed by reaction with the amine onto the microcapsule film.
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This patent application is being filed as a conversion of provisional application Ser. No. 60/087,257 filed May 29, 1998 and provisional application Ser. No. 60/122,441 filed Mar. 2, 1999. All disclosures and information contained in both provisional applications are expressly incorporated herein.
The present invention relates to an automatic cassette wrapping and assembly machine for use in manufacturing video cassettes, including but not limited to the type disclosed in U.S. Pat. No. 5,311,388. For the purposes of this patent application and description, the invention will be described for the wrapping and assembly of VHS-type tape cassettes. However, the description is not intended to be limiting upon the scope of the claims which are appended hereto.
It has long been an objective in the audio and video duplication industry to provide for the enhanced manufacture and assembly of cassettes, tapes and their labeling and packaging. Commonly, such cassettes and tapes receive labeling which is adhered directly to the cassette or tape body and the labeled cassette or tape is then placed in corrugated packaging having labeling and graphics applied thereto. Need for the corrugated sheath or container for such cassettes and tapes has been eliminated by cassettes of the type shown in U.S. Pat. No. 5,311,388. Cassettes or tapes of the type shown in the '388 patent have a sheath or label which is applied to the outer surfaces of the cassette or tape which include the complete graphics and labeling, thereby eliminating the need for the outside cover. The cassette of the '388 patent is simply labeled and wrapped in clear wrap to seal its surfaces prior to shipping. Such cassettes, to date, are time-consuming in their manufacture and use as the outer sheath or label is usually hand applied. Thus, there is a need for an automatic cassette wrapping and assembly machine which performs the steps of applying the sheath to the cassette in a rapid, repetitive automated fashion.
SUMMARY OF THE INVENTION
The present invention provides an automatic cassette wrapping and assembly machine generally composed of three stations: a station for loading cassettes and inserting cassettes into the assembly line; a sheath assembly and wrapping station; and a discharge and stacking station.
The loading and insertion station includes a magazine in which the cassettes are loaded and stacked. The magazine described herein has a capacity to retain rows of 60 units with a capacity of ten rows, thus providing for 600 cassettes in a fully loaded magazine. However, magazine capacity may be designed to meet demand. The machine, as described herein, is designed to process a minimum of 60 cassettes per minute, thereby a fully loaded magazine provides a ten minute operative capacity. A lowering and insertion member is designed to support the rows of stacked cassettes and insert one row at a time onto a feed conveyor member which transports the row of cassettes to the assembly station. The feed conveyor member is provided with a continuous belt and includes a guide member which prevents the row of cassettes from slipping out of position. The conveyor member is driven by stepper motors which receive drive inputs from a central processing unit, the inputs being regulated by sensing devices positioned to determine the relative positioning of cassette members throughout the machine. The sensors monitor the flow of cassettes on the conveyor and are used to signal when the conveyor is clear for insertion of another row of cassettes. Other sensors are used to monitor for the proper orientation and positioning of the cassettes as they approach the assembly station.
The assembly station is comprised of a flight conveyor which receives the cassettes from the feed conveyor and lifts the cassettes vertically into a compression conveyor. A sheath prefold and glue applicator apparatus operates in cooperation with the flight conveyor and compression conveyor. The flight conveyor includes a series of lift members driven by motors, preferably stepper motors programmed to move the distance of one cassette at a time, which carry a single cassette into an aligning track and into the compression conveyor. The compression conveyor receives the cassette which has engaged with a sheath having preapplied glue positioned at the mouth of the compression conveyor. As the cassette and sheath move through the compression conveyor, the pre-glued sheath is compressed and wrapped around the cassette. Sensors monitor the positioning of the cassettes and sheath and provide information signals to the central processing unit related to the cassette positioning on the flight conveyor; cassette positioning in the compression conveyor; sheath positioning and orientation; and cassette engagement with the sheath.
As the cassettes are approaching the flight conveyor and being positioned through engagement with the flight conveyor and aligning track, the sheath prefold and glue application apparatus is feeding sheath members with preapplied glue into position proximate the entrance to the compression conveyor for engagement with each approaching cassette. Individual sheaths are removed from a stack and each sheath is prefolded along scored lines and then straightened. The prefolded and straightened sheath receives an application of glue and is driven into its final position at the entrance to the compression conveyor. Again, sensors are positioned in the sheath transfer and glue application system to ensure proper positioning of the sheath with respect to the oncoming cassette, positioning of the sheath through the prefolding, straightening and gluing steps and for providing signals regarding the presence of defective and improperly positioned sheaths. After a sheath is positioned at the mouth of the compression conveyor, a cassette will be fed into the compression conveyor by the flight conveyor, first engaging the sheath along the spine of the cassette and then pressing the top flap, bottom flaps and end flaps of the sheath into engagement with the top surface, bottom surface and ends of the cassette respectively as the cassette and sheath move through the compression conveyor. It is envisioned that a quality control sensor to monitor the precise sheath wrap position on each finished cassette as the cassette exits the compression conveyor. As the cassette wrapped in the sheath exits the compression conveyor, it is guided onto a horizontally oriented compression chute having spaced rows of resilient fins designed to provide continuous pressure to the spine and ends of the sheath, thereby providing constant compression allowing the sheath and glue to set in position, thereby permanently bonding the sheath to the cassette.
As the cassette exits the compression chute, it is flipped to a horizontally oriented position onto a positioning conveyor which relays the cassette to the stacking station. The stacking station includes a bin having a vertically moving floor and an aligning and orienting apparatus located at the top of the bin. The aligning and orienting apparatus receives the cassettes from the positioning conveyor and orients them in rows of a preset number. As each row of cassettes becomes filled, a release mechanism is activated to drop the row of cassettes onto the floor of the stacking bin which is positioned immediately under the aligning and orienting apparatus. After each row of cassettes is deposited onto the floor of the stacking bin, sensors signal the central processing unit to activate a lift mechanism to lower the floor of the bin one cassette level to allow the next row of cassettes to be received from the aligning end orienting apparatus. After the bin is full, the stack of cassettes is ejected into an appropriate container and the floor of the bin is raised back to its starting position.
The present invention can be further appreciated by reference to the following description of the preferred embodiment of the invention with reference to the accompanying drawings. While the current embodiment, as described, dictates the use of specific types of drive mechanisms, motors and rollers, it is fully envisioned that the substitution of equivalent structure for the pneumatic lifts, stepper motors, servo motors, drive motors, compression rollers, conveyor belts, lift members, chain drives, gear and sprocket drives and sensors may be substituted without departing from the scope and overall vision of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the cassette wrapping and assembly machine of the present invention.
FIG. 2 is a front view, partially in ghost, of the cassette magazine and feed conveyor.
FIG. 3 is a side view of the cassette loading and insertion magazine showing the cassettes supported in an upraised position.
FIG. 4 is a side view of the cassette loading and insertion magazine showing the cassettes lowered to a position for placement on the feed conveyor.
FIG. 5 is a side view of the cassette loading and insertion magazine showing the positioning of the insertion member for placing the cassette row on the feed conveyor.
FIG. 5A is a side view of the cassette loading and insertion magazine showing the first row of cassettes partially inserted to the feed conveyor, while the next row of cassettes is supported by the insertion member.
FIG. 6 is a side view of the cassette loading and insertion magazine showing the insertion member fully extended to place a row of cassettes on the feed conveyor.
FIG. 7A is a partial side view of the front portion of the sheath prefold and glue application apparatus.
FIG. 7B is a partial side view of the remaining portion of the sheath prefold and glue application apparatus.
FIG. 8A is a partial cutaway side view of the cassette flight conveyor and compression conveyor and horizontally oriented feed and compression conveyor.
FIG. 8B is a partial cutaway side view of the continuation of the horizontally oriented feed and compression conveyor, positioning conveyor and stacking station.
FIG. 9 is an end view showing the stacking station of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the automatic cassette wrapping and assembly machine of the present invention includes the following components. A cassette loading and insertion apparatus 10 is positioned to retain stacked rows of cassettes for placement, one row at a time, onto the feed conveyor 20 . The magazine 11 of the cassette loading and insertion apparatus 10 will provide capacity for ten stacked rows of VHS cassettes, each row containing sixty units. Thus, a fully loaded magazine 11 will contain 600 cassettes. All surfaces of the cassette loading and insertion apparatus 10 are preferably constructed of a hard canvas-based phenolic sheet chosen for its strong wear characteristics and its ability to provide a smooth non-abrasive surface on which the cassettes may slide, thereby preventing marking and any undesirable damage to the plastic cassette cases. It should be noted that all non-functioning and non-moving parts of the machine are preferably constructed of the same canvas-based phenolic sheet.
The feed conveyor 20 extends the length of the cassette loading and insertion apparatus 10 as shown in FIG. 2 and feeds to the assembly station 30 as shown in FIG. 8 A.
Referring back to FIG. 1, the assembly station 30 includes a flight conveyor 27 , shown in FIG. 8A, a compression conveyor 28 , shown in FIG. 8A, and a sheath prefold and glue applicator apparatus 50 positioned adjacent the flight conveyor 27 and the compression conveyor 28 as shown in FIGS. 1 and 8B. Finally, as shown in FIGS. 1, 8 B and 9 , a compression chute 57 is positioned downstream of the compression conveyor 28 and combines with a positioning conveyor 60 to feed the fully assembled cassettes to the stacking station 61 . The operation of the automatic cassette wrapping and assembly machine is controlled by a central processing unit 100 .
Referring now to FIG. 2, the magazine 11 of the cassette loading and insertion station 10 is formed to have opposed sidewalls 12 and a backwall 13 . The backwall 13 includes a slot 14 which runs the length of the backwall 13 and is slightly higher than the width of a standard VHS cassette, as shown in FIGS. 3-6. A lowering and insertion member 15 built for movement in the vertical and horizontal directions serves as the primary support for the vertically stacked rows of cassettes. The lowering and insertion member 15 includes a vertical elevator 16 which is raised and lowered by a pneumatic piston 17 . A horizontally actuated support and insertion platform 18 , driven by a pneumatic piston 19 is carried by the vertical elevator 16 . The non-functional surfaces of the insertion and support platform 18 are constructed of the same canvas-based phenolic sheet to ensure a smooth non-abrasive surface on which the cassettes may slide. A lip member 21 is located across the bottom of the open front of the magazine 11 and is designed to engage the bottom most row of cassettes, thereby ensuring that all the cassettes are properly aligned when being lowered by the lowering and insertion member 15 for insertion onto the feed conveyor 20 .
Referring now to FIGS. 3-6, the operation of the cassette loading and insertion station 10 can be ascertained. FIG. 3 shows the cassette loading and insertion station 10 at its start position, wherein the rows of cassettes which are stacked in the magazine 11 are supported by the top surface of the support and insertion platform 18 . A row of cassettes is shown in position on the feed conveyor 20 which are being fed to the assembly station 30 . The insertion and support platform 18 is then vertically lowered by means of the elevator 16 and its piston 17 as shown in FIG. 4, thereby lowering the stacked rows of cassettes to now rest in position on the magazine floor 22 . As the bottom row of cassettes engage and is supported by the floor 22 of the magazine, it aligns with the slot 14 in the back wall 13 of the magazine 11 . The magazine floor 22 is supported by a piston 23 which activates to move the floor vertically an approximate distance of ¼ to ½ inch. After the cassettes are in a position of support on the magazine floor 22 as shown in FIG. 4, the insertion and support platform 18 is withdrawn from engagement with the bottom row of cassettes by its piston 19 and is vertically raised by the elevator 16 and piston 17 to be positioned immediately behind the bottom row of cassettes as shown in FIG. 5 . The central processing unit, when signalled by the appropriate sensors (not shown) that the feed conveyor 20 is vacant, will activate the piston 19 to horizontally displace the insertion and support platform 18 to begin pushing the bottom row of cassettes through the slot 14 . As shown in FIG. 5A, the insertion and support platform 18 pushes the bottom row of cassettes through the slot 14 , and will begin supporting the immediately adjacent next row of cassettes on its top surface. As the next row of cassettes engage the top surface of the insertion and support platform 18 , the central processing unit activates the piston 23 supporting the magazine floor 22 to lower the magazine floor 22 approximately ¼ to ½ inch, thereby relieving pressure between the bottom row of cassettes and the forces being applied by the weight of the stacked rows of cassettes now being supported by the insertion and support platform 18 as shown in FIG. 5 A. The insertion and supporting platform 18 will continue pushing the bottom row of cassettes to the feed conveyor 20 across the magazine floor 22 while supporting the stacked rows of cassettes as shown in FIG. 6 . Once the bottom row of cassettes is in position on the feed conveyor 20 , the insertion and support member 18 will be withdrawn to its original starting position as shown in FIG. 3 . The magazine floor 22 will vertically return to its starting position, thereby providing a guide surface 24 for the row of cassettes as they travel along the feed conveyor 20 . A guide member 25 is positioned on the opposed side of the feed conveyor 20 to work with the guide surface 24 and properly align the cassettes as they proceed along the feed conveyor 20 to the assembly station 30 .
Sensing devices (not shown) such as light emitting diodes or polarized infrared scanners are positioned in the magazine 11 to signal when the last row of cassettes has exited the magazine, the signal being sent to the central processing unit 100 to notify the operator to refill the magazine 11 . Further sensors (not shown) are positioned about the feed conveyor 26 to monitor the flow of cassettes on the feed conveyor 20 and provide signals to the central processing unit when the feed conveyor 20 is clear for insertion of another row of cassettes and monitor the cassettes placed on the feed conveyor 20 to insure proper orientation and positioning of the cassettes as they approach the assembly station 30 . The conveyor guides 25 are preferably constructed of ultrahigh molecular weight polyethylene. The conveyor belts 26 of the feed conveyor 20 , as are all other conveyor belts of this invention, are constructed of true Teflon, the ends of which are laced together with a flush lacing designed to prevent tipping or otherwise disturbing the flow of cassettes to the assembly station 30 . The feed conveyor 20 is operated by motors 73 , preferably stepper motors, which index the feed conveyor belt 20 one cassette width at a time toward the assembly station 30 .
Referring to FIG. 8A, the assembly station 30 includes two conveyor sections which act in unison to assemble the cassettes and sheaths. A flight conveyor 27 is positioned proximate the end of the feed conveyor 20 to receive cassettes as they are indexed to the assembly station 30 . The flight conveyor 27 provides a vertical lift to each cassette and processes it into engagement with a prefolded, straightened and preglued sheath 40 positioned at the mouth of a compression conveyor 28 . The flight conveyor 27 includes a series of lift members 29 positioned on a belt or chain 31 which is preferably driven by a stepper motor 32 . The flight conveyor 27 also includes an aligning track 77 constructed of a Teflon material such as Delrinm which engages the ends of the cassettes and guides the cassettes in a desired orientation to the compression conveyor 28 . The stepper motor 32 receives signals from the central processing unit 100 which direct it to index the flight conveyor 27 one cassette at a time. Sensors 33 , such as infrared or light emitting diodes, monitor the positioning of the cassettes relative to the flight conveyor 27 . The sensor 33 provides a signal to the central processing unit which in turn provides input to a stop member 34 which, when activated, engages the cassette on the feed conveyor 20 to prevent the cassette from engaging the lift members 29 of the flight conveyor 27 until all systems of the machine are readied for operation and the cassettes are inspected for proper orientation by appropriate sensors. Preferably, the lift members 29 of the flight conveyor 27 are spring loaded, thereby providing engaging surfaces which create a cushioning effect when the cassettes are engaging each other in the aligning track 77 to prevent overloading the stepper motors driving the flight conveyor 27 . The central processing unit 100 receives signals from the various sensors and coordinates the operation of the stepper motors 73 which drive the feed conveyor 20 , the stepper motors 32 which drive the flight conveyor 27 , and the motors 26 which drive the sheath conveyor 36 and the motor (not shown) which drive the compression conveyor 28 . If the central processing unit 100 receives appropriate signals from the sensors that a cassette is in proper alignment with the flight conveyor 27 , the stop member 34 is signaled to release the cassette to be moved by the feed conveyor 20 into engagement with the lift members 29 of the flight conveyor 27 . The cassette is then transported by the flight conveyor 27 into the aligning track 77 toward the compression conveyor 28 . At the same time, a paper board sheath 40 is transported by the sheath conveyor 36 to a position immediately proximate the mouth of the compression conveyor 28 . The paper board sheath is engaged with the spine of the cassette at the entrance to the compression conveyor 28 . As the cassette and sheath 40 are carried into the compression conveyor 28 , the spine of the cassette and sheath are pressed against the immediately preceding cassette already in the compression conveyor, thereby compressing the paper board sheath 40 against the spine of the cassette.
The compression conveyor 28 is preferably constructed of opposed Teflon belts 37 carried by low crush rollers 38 and a plurality of flexible fins 39 positioned so as to provide continuous compressive forces against the sheath covered cassette as it travels through the compression conveyor 28 thereby causing the sheath to adhere to the cassette.
Referring now to FIGS. 7A and 7B, the sheath prefold and glue applicator apparatus 50 is shown. A stacking member 39 for retaining a stack of paper board sheaths which have the graphics for the particular video cassette preapplied includes a spring loaded elevator 41 which continuously raises as the sheaths 40 are removed from the stack. Vacuum pickups 42 remove the top sheath 40 from the stack of sheaths and place it into engagement with a positive drive roller 43 as shown in FIG. 7A. A sensor 44 determines the presence of sheaths in the stacking member 39 and if there are no sheaths remaining, the sensor 44 signals the central processing unit 100 to temporarily deactivate the machine until the stacking member 39 is replenished with sheaths. The sheath 40 is generally constructed of paperboard with appropriate graphics applied to one side. The sheath is precut and scored to provide the appropriate folding and openings necessary to properly encase the cassette.
After the sheath is driven through the positive drive roller 43 it engages a drive conveyor 45 which engages the spine of the sheath and drives the sheath through a folding station and an unfolding station. The drive conveyor 45 will support the sheath between a moving conveyor belt 74 and rollers 46 . As the sheath proceeds downstream from the positive drive roller 43 it first engages a prefold arm 47 which forces the sides of the sheath to fold along the scored lines which parallel the spine of the sheath. Upon exiting the prefold arm 47 and having a prefold placed along the scored line, the sheath engages a straightening arm 48 which unfolds and straightens the prefolded sheath. The straightened sheath is now limbered along its prefold scores which will enhance the ability of the sheath to fully encompass and adhere to the cassette in the compression conveyor 28 . After the sheath exits the straightening arm 48 , it is engaged by drive rollers 49 which propel the sheath past a glue application apparatus 51 . The glue application apparatus 51 includes a glue pot 52 , a feeding wheel 53 engaged with the glue pot 52 and a final glue application roller 54 which applies a measured amount of glue onto the non-graphic portion of the sheath on specified areas only. Preferably, the edges of the sheath are kept clean from glue so that, as the sheath is applied to the cassette in the compression conveyor 28 , excess glue will not be squeezed from the edges of the sheath onto the cassette or the drive mechanism of the machine. An opposed pair of driven Teflon belts 36 engage the sheath with glue applied, as it exits the glue application apparatus 51 , along the edges of the sheath to drive the sheath into its final position located at the entrance or mouth to the compression conveyor 28 . The parallel drive belts 36 which engage the edge of the sheath are positioned to apply a slight pressure to the sheath thereby causing the sheath to slightly fold or buckle along its scored lines, thereby enhancing adherence of the sheath to the cassette as the cassette engages the sheath by movement from the aligning track 77 to the compression conveyor 28 .
Appropriate sensors (not shown) are used to ensure that the glue pot maintains sufficient quantities of glue and to ensure proper positioning of the sheath with respect to the oncoming cassette at the mouth of the compression conveyor 28 . The sheath is also monitored as it passes through the prefold arm, straightening arm and drive rollers as well as the gluing station to ensure that the sheath maintains proper orientation and there are no defective sheaths entering the mouth of the compression conveyor 28 . If a defective sheath is located, the drive belts 36 are signaled by the central processing unit to reject the sheath from the assembly station 30 .
The operation of the assembly station can be followed by viewing FIGS. 7B and 8A. As the cassette is engaged by the flight conveyor 27 and lifted toward the aligning track 77 and compression conveyor 28 , the sheath 40 with preapplied glue is driven by the drive belts 36 into position at the mouth of the compression conveyor 28 . The cassette spine engages the spine of the sheath as the cassette is driven into the compression conveyor 28 . The top flap and bottom flap of the sheath are then pressed into engagement with the top surface and bottom surface of the cassette as the sheath and cassette are moved into the compression conveyor 28 between the low crush rollers 38 and Teflon belts 37 . Flexible fin members 39 are located along the travel path between the low crush rollers 38 and Teflon belts 37 continue the pressure on the Teflon belts 37 between the low crush rollers 38 . Flexible end fins 55 , shown in FIG. 7B, provide continuous pressure to the end flaps of the sheath, thereby pressing the end flaps of the sheath into engagement with the ends of the cassette. Thus, as the sheath encased cassette travels through the compression conveyor, the sheath is completely adhered to the cassette. The Teflon coated belts 37 are used throughout the compression conveyor 28 and other conveyor systems as they are impervious to the glue and any excess glue which may be squeezed from the cassettes and sheaths can be readily wiped off.
It is envisioned that automatic wipers for the Teflon belts 37 will be made as part of the overall apparatus of the invention.
As the sheath encased cassette exits the compression conveyor 28 , as shown in FIG. 8A, it enters a horizontally oriented compression chute 57 which maintains the cassette in an upright vertical position. A pushplate 78 driven by a pneumatically powered piston 79 engages each cassette as it exits the compression conveyor 28 and directs the cassette into the compression chute 57 . The compression chute 57 is designed to compress the top surfaces and bottom surfaces of adjacent cassettes together to facilitate the setting of the glue and final formation of the sheath application to the cassette. Further, rows of spaced resilient fins 58 are positioned to provide continuous pressure to the spine and ends of the cassette thereby applying continuous pressure to the spine and ends of the sheath, allowing the glue to set and permanently bond the sheath to the cassette. The resilient fins 58 may be constructed of any resilient and durable material.
Referring now to FIGS. 8B and 9, the sheath wrapped cassette exits the compression chute 57 and is flipped by a stop arm 59 to a horizontally oriented position and into engagement with a positioning conveyor 60 . It should be noted that the positioning conveyor 60 is constructed of polyurethane belts and is driven by motors 76 such as stepper motors which receive signals from the central processing unit to move the cassettes one cassette unit at a time. The positioning conveyor 60 feeds the final cassette products to the stacking station 61 which includes a bin 62 having side walls 63 and a vertically moveable floor 64 . Located at the top of the bin 62 in an area adjacent the positioning conveyor 60 is an aligning and orienting station 65 . The aligning and orienting station 65 includes support members 66 which receive the cassettes as they are being positioned at the top of the bin 62 . The aligning and orienting station 65 positions a preset number of cassettes for placement into the bin 62 . Appropriate sensors (not shown) provide signals to the central processing unit which indicate when the aligning and orienting station 65 has received its full compliment of cassettes. At that time a pneumatic piston 67 engaged with the support rails 66 of the aligning and orienting station 65 is signaled by the central processing unit to separate the support rails 66 apart, thereby releasing the row of cassettes to drop onto the floor 64 of the stacking bin 62 which is positioned immediately under the support rails 66 . A set of stops 68 located at the end of the positioning conveyor 60 are signalled by the central processing unit to close and prevent movement of cassettes from the positioning conveyor 60 onto the aligning and orienting station 65 when the aligning and orienting station 65 is full and the row of cassettes is being dropped to the floor 64 of the bin 62 .
The floor 64 of the bin 62 is supported by a pneumatic piston 69 and controlled by the central processing unit 100 to maintain a position immediately under support rails 66 of the aligning and orienting station 65 . After each row of cassettes is deposited onto the floor 64 of the bin 62 , a sensor (not shown) signals the central processing unit which in turn signals the lift piston 69 to lower the floor 64 of the bin 62 down one level of one cassette thickness, thereby allowing room for the next row of cassettes to be received from the aligning and orienting station 65 . Finally, the bin 62 includes a push wall 70 driven by a pneumatic piston 71 which is operated by signals from the central processing unit 100 . When sensors (not shown) positioned in the bin 62 indicate that the bin 62 is full of stacked rows of completed cassettes, the controller signals the piston 71 to drive the push wall 70 through the bin 62 thereby pushing a ready stack of cassettes onto the packaging table 72 . The floor 64 of the bin is then raised by its piston 69 back to its starting position.
While the current embodiment of the invention as described above dictates the use of specific types of drive mechanism, motors, rollers and sensors, it is fully envisioned that the substitution of equivalent structures for the pneumatic lifts, stepper motors, drive motors, compression rollers, conveyor belts, lift members, chain drives and gear and sprocket drives as well as any other structure in the invention, as shown in the figures, may be substituted without departing from the scope and overall vision of this invention.
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An automatic cassette wrapping machine includes three interconnected stations: a station for loading cassettes and inserting cassettes into an assembly line; a station for receiving the cassettes and engaging the cassettes with paperboard sheaths having preapplied glue; and a station for receiving the sheath encased cassettes and stacking the cassettes in shippable pluralities. The cassette assembly machine is fully automated and includes a central processing unit receiving signals from sensors positioned throughout the machine to coordinate all aspects of machine operation.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional application 62/099,758 filed Jan. 5, 2015, and hereby incorporated, in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of processing nanoparticles for use in multiple applications.
[0003] Recent decades have brought about reliable, methods for the synthesis and functionalization of metal nanoparticles but applying these nanoparticles to many important applications has been hindered by the difficulty of organizing the particles into regular structures with controlled interparticle spacing, for example, as needed to optimize electronic conductivity. Similarly, precise interparticle spacing can be important to control the optical transport properties of these nanoparticles.
[0004] It is generally known to functionalize nanoparticles for the purpose of applying a targeting ligand to the nanoparticles encouraging accumulation of the nanoparticles, for example, in a tumor. The nanoparticles may then serve, for example, as selective absorbers of radiation (for example, microwave radiation) for hyperthermic treatments.
SUMMARY OF THE INVENTION
[0005] The present invention provides: (1) a method of constructing films of nanoparticles with controlled interparticle spacing for incorporation into structures such as solar cells and (2) a method of restraining nanoparticles for sophisticated functionalization, for example, using two different functionalizing agents of an anticancer agent and a targeting agent on each nanoparticle so that nanoparticles can be delivered to a tumor site with an anticancer agent that may be activated by heat from the nanoparticles.
[0006] These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a flowchart and associated diagram showing the fabrication of a transparent conductive oxide solar cell augmented with gold nanoparticles;
[0008] FIGS. 2 a - c are representations of functionalized gold nanoparticles on an air water interface (shown in cross-sectional elevation), the nanoparticles functionalized for cross-linking to limit diffusion and rotation;
[0009] FIG. 3 is a figure similar to that of FIG. 2 showing introduction of a water-soluble functional group to only one side of the immobilized nanoparticles;
[0010] FIG. 4 shows bi-functionalized nanoparticles such as may provide for both an anticancer agent and a targeting agent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Photovoltaic Cell
[0011] Referring now to FIG. 1 , a process 10 for fabrication of photocells ma provide for the construction of a solar cell substrate 12 per process block 14 , for example, including assembling in parallel adjacent layers of dissimilarly doped semiconductor elements 16 and 18 forming a PN junction.
[0012] In parallel with the above process and possibly in a different facility that does not need traditional integrated circuit processing technologies and which would not suffer from contamination problems caused by nano conductors, a nanoparticle film 20 may be fabricated as indicated by process block 17 . This film 20 may be fabricated, for example, through the use of a Langmuir trough 22 of the type having a tray holding water 24 on whose surface functionalized hydrophobic nanoparticles 26 may be introduced, for example, in a solution of hexanes to arrange themselves along an air water interface 28 .
[0013] Nanoparticles 26 , fur example, may be gold nanoparticles functionalized with thiols, for example, providing the hydrophobic property. The nanoparticles 26 may have a size varying from 3 to 8 nanometers and may be synthesized using a Brust synthesis. Purification to eliminate excess thiols and phase transfer reagents is performed using the Soxhlet extraction technique.
[0014] Barriers 30 on the trough 22 corralling the nanoparticles 26 along the surface of the water 24 may then be isometrically contracted together to compress the nanoparticles 26 into a desired film having a controlled average interparticle spacing and cross-linking agents such as a dithiol or bisdithiol or mixture of the same (and alternatively possibly being diphosphines or diamines) may then be introduced to form cross-links between the nanoparticles 26 connecting them into a robust monolayer 34 . An upper or lower surface of the monolayer 34 may then be modified to make it hydrophilic as will be discussed below, with the cross-linking preventing diffusion of the nanoparticles 26 into the water 24 .
[0015] The solar cell substrate 12 , for example, having an outer surface of silicon oxide or silicon nitride, can be drawn through the monolayer 34 which then adheres to the broad faces of the substrate 32 , utilizing the Langmuir-Blodgett method of monolayer transfer to a solid substrate. For example when the lower surface of the monolayer 34 is made hydrophilic, when the substrate 32 is drawn vertically out of the water 24 through the air water interface 28 a monolayer 34 will be deposited and adhered on its opposite surfaces. During this withdrawal, the barriers 30 may be moved together to preserve the desired density of nanoparticles 26 . Conversely, the upper surface of the monolayer 34 may be made hydrophilic and the substrate passed vertically downward through the air water interface 28 . The result is a thin film with a controlled spacing of nanoparticles 26 adhered to the upper surface of the substrate 12 opposite the backer electrode 21 . The same result may also be achieved using a Langmuir-Schaffer transfer, by which a substrate is oriented parallel to the air-water interface, lowered until contact is made, and then withdrawn from the interface, leaving the hydrohphilic side of the film bonded to the substrate.
[0016] At process block 38 , a layer of a transparent conductive oxide 40 (for example, indium tin oxide) may be sputtered over the nanoparticles 26 to provide a composite conductive electrode 42 on opposite sides of the solar cell substrate 12 for collection of electrical current and the driving of a load. The gold nanoparticles 26 provide improved capture of light energy either by absorption and retransmission or internal reflection. A gram of gold nanoparticles can provide coating for 4000 square meters of transparent conductive oxide. Alternatively, the crosslinked film of gold nanoparticles may be applied to a previously constructed solar cell, where the film would prevent captured light from escaping the cell, thus increasing the dwell time of the incoming radiation and in turn increasing photocarrier generation.
Drug Delivery System
[0017] Referring now to FIGS. 2 a - c, thiol functionalized gold nanoparticles 26 in the Langmuir-Blodgett trough 22 described above may be compressed together to get the desired separation as indicated by FIG. 2 . The thiol functionalization 27 . as discussed above, provides a hydrophobic quality to the gold nanoparticles 26 causing them to align along the air water interface. The nanoparticles 26 may be compressed to desired density using the barriers 30 (shown in FIG. 1 ) and joined into a monolayer 34 with a cross-linking agent 29 being for example a dithiol or bisdithiol or combination for example as described in paper [1] cited below and hereby incorporated by reference. The cross-linking agent 29 may be introduced in a layer of chloroform (CHCl 3 ) may be applied over the water 24 (as shown in. FIG. 2 b ) and then allowed to evaporate as shown in FIG. 2 c to promote a cross-linking of the spaced nanoparticles 26 . A polar peptide on the cross-linking agent 29 helps the agent lie flat on the surface of the water 24 . This cross-linking provides two benefits of restricting rotation of the nanoparticles 26 and preventing their diffusion into the water 24 as would otherwise occur when there hydrophobic nature is modified by a ligand exchange process discussed below.
[0018] Referring now to FIG. 3 , after this cross-linking, new functionalization groups 51 can be introduced into the water 24 in contact with the previous functionalization of the nanoparticles 26 with the thiol functionalization to provide an exchange of ligands. For example, an ethanolic solution of mercaptohexanoic acid can be injected into the aqueous sub phase (the water 24 ) and the excess mercaptohexanoic acid will displace the short chain alkanethiol via a ligand exchange process to provide for asymmetric functionalization of each nanoparticle 26 . This particular ligand exchange provides a hydrophilic surface to the monolayer 34 .
[0019] Conversely, the distal ends of the upper thiol functionalization of each nanoparticle 26 may be modified by through the introduction of a carrier fluid 54 (for example hexanes) over the surface of the water 24 providing a layer immiscible with the water 34 but acting as a solvent to hold the ligands for exchange with the upper thiol functionalization. Generally, the carrier fluid 54 is selected to be non-soluble in the water 24 but to provide a solvent for the desired ligand for exchange.
[0020] Referring now to FIG. 4 , this regioselective ligand exchange process may be used to produce a so-called Janus nanoparticle 52 having different sides with different functionalizations R 1 and R 2 . In one case, one functionalization may provide for a hydrophilic side to the monofilm 34 for attachment to the substrate 12 discussed above.
[0021] Alternatively, one functionalization (R 1 ) may provide for an anticancer agent that works in conjunction with hyperthermia treatment made possible using the nanoparticle 26 and the other functionalization (R 2 ) may be a targeting ligand allowing the Janus nanoparticles 52 to be preferentially retained in a tumor 56 where the anticancer agent and heat therapy may be delivered.
[0022] Referring again to FIG. 3 , for this latter purpose, a photo-cleavable cross-linking element 60 may be incorporated into the cross-linking between nanoparticles 26 to allow individual nanoparticles 26 to be extracted by light exposure. For example the photo-cleavable cross-linking element 60 may be nitrobenzyl photo-cleavable linker introduced in the hydrocarbon chain between the sulfur groups of the cross-linking agent 29 .
[0023] These techniques can be extended to arrays of anisotropic nanomaterials such as nanorods, whose optical properties are expected to be dependent upon final orientation (either side-by-side or end--to-end) of the finished crosslinked composition. It will be generally understood that various techniques can be applied to the gold nanoparticles 26 to improve their ability to absorb radiation and in particular lower frequency microwave radiation as opposed to visible light radiation. These techniques increase the electrical size of the nanoparticles 26 for example through the use of a shell structure (nano shell).
[0024] The present application hereby incorporates the following materials in their entirety by reference:
[1] Langmuir isotherms of flexible, covalently crosslinked gold nanoparticle networks: Increased collapse pressures of membrane-like structures by Tayo A. Sanders II, Mariah N. Sauceda, Jennifer A. Dahl Materials Letters 04/2014; 120:159-162. DOI: 10.1016/j.matlet.2014.01.056; and [2] Microwave synthesis of a bimodal mixture of triangular plate and spheroidal silver nanoparticles by Anneliese E. Laskowski Daniel A. Decato Mitchel S. Strandwitz Jennifer A. Dahl MRS Communications, 05/2015; 5(2):1-7. DOI: 10.1557/mrc.2015.23.
[0027] Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
[0028] When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended, to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0029] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications, are hereby incorporated herein by reference in their entireties.
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The manipulation of nanoparticles is facilitated through the use of a Langmuir-Blodgett trough constraining the nanoparticles to two dimensions and allowing their density to be controlled through the barriers of the Langmuir-Blodgett trough. A film formed in this manner can be applied to enhance a transparent conductive electrode on the photovoltaic cell. Alternatively the nanoparticles as so constrained can be given two types of functionalization, for example, of an anticancer agent and a targeting ligand.
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BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention has relation to a portable liquid storage and dispensing unit which can store fluids such as soap, shampoo, and conditioning rinse until needed; and can then be used to selectively dispense these fluids as needed during the bathing process.
2. Description of the Prior Art.
It is known to support a dispenser on a shower stall wall by suction cups, the dispenser having separate compartments for shampoo and rinse. See U.S. Pat. No. 3,920,160 to Casale et al. issued in November of 1975, FIGS. 4 and 6. Use of a suction cup to hold toilet articles is also shown in U.S. Pat. No. 2,883,062 issued to Rosemark in April of 1959.
Various manually pressure activated containers mounted on walls to dispense fluids are shown in the above mentioned patent to Rosemark and in the following U.S. Pat. Nos. 3,078,016 issued to Judy in February of 1963; 3,078,017 issued to Waskonig et al. in February of 1963; 4,166,553 issued to Fraterrigo in September of 1979; and 4,470,523 issued to Spector in September of 1984. This Spector patent shows a flexible, resilient container encompassing a single compartment containing liquid soap, the container being more or less permanently attached to a kitchen or bathroom wall by adhesive, the liquid being dispensed from the container by exerting manual pressure on it.
Combining a collapsible fluid container with a sponge is shown in U.S. Pat. No. 3,143,755 issued to Rowley in August of 1964 and in U.S. Pat. No. 3,276,067 issued to Boyle et al. in October of 1966.
Other patents cited in the search for this invention as being of general interest, but not showing the elements of this invention include U.S. Pat. No. 3,349,967 issued to Schneller in October of 1967 and U.S. Pat. No. 3,990,611 issued to Sojka in November of 1976.
What was needed before the present invention was a squeezable fluid contaienr with several compartments, each having its own closable outlet port made so that applying manual pressure to a resilient wall of the container will cause liquid to be dispensed from which ever one of its compartments was open.
Also, before this invention, there was no such structure accomplishing the purposes set out above which would, when the unit was positioned for storage, be so assembled that all outlet ports are situated so that they cannot be accidentally accessed and opened to the end that fluids from the container and from a sponge connected to the container cannot escape from the unit.
SUMMARY OF THE INVENTION
A unit for storage and dispensing of fluids includes a container which is at least partially resilient and which encompasses a plurality of separate, fluid tight, fluid containing compartments, these compartments being at least partially defined by flexible walls, and each compartment having a flexible or otherwise deformable wall in intimate contact with at least one of the other compartments. A normally closed, openable port extends from each of the compartments.
The container includes a resilient wall which is manually temporarily deformable to tend to reduce the volume of each compartment to develop a pressure in each compartment such that fluid will be dispensed through any compartment port that is open while the other ports remain normally closed.
In the form of the invention as shown, three compartments (containing liquid soap, shampoo, and a conditioning rinse, for example) are encompassed by a container which is resilient on top, bottom, and side walls and a front wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a storage and dispensing unit for fluids made according to the present invention;
FIG. 2 is a vertical sectional view taken on the line 2--2 in FIG. 1 showing the unit in condition to be stored;
FIG. 3 is a vertical sectional view also taken on the line 2--2 in FIG. 1 but showing the unit in condition for dispensing shampoo or creme rinse and for allowing water and liquid soap to drain from a sponge forming part of the unit;
FIG. 4 is a horizontal sectional view taken on the line 4--4 in FIG.3; and
FIG. 5 is a vertical sectional view taken on the line 5--5 in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A portable personal liquid storage and dispensing unit 10 includes a rectilinear container 12 of configuration to fit snugly inside of a rectilinear open face case 14. In the form of the invention as shown, this container encompasses three fluid tight compartments, namely, a liquid soap compartment 16, a shampoo compartment 17, and a creme rinse compartment 18. These compartments contain liquid soap 20, shampoo 21, and creme rinse 22, respectively. The unit of the invention would work satisfactorily if one or more of the compartments contained a fluid such as a paste, cream or gel, for example.
Rectilinear container 12 includes a resilient top wall 24, a resilient bottom wall 25, a first resilient side wall 26, a second resilient side wall 27, a resilient front wall 28, and a back wall 29.
In the form of the invention as shown, a resilient bifurcated wall 30 extending integrally between the container side walls 26 and 27, bottom wall 25, front wall 28 and back wall 29 separate the liquid tight compartments 16, 17 and 18 from each other.
A sponge 32 is permanently affixed to the back wall 29 in any usual or preferred manner, and is provided with a soap access opening 34 therethrough.
Each of the fluid tight, fluid containing compartments is provided with a port opening outwardly from that compartment. Soap compartment 16 is provided with a soap dispenser port 36 open to the soap access opening 34 in the sponge 32; shampoo compartment 17 is provided with a shampoo dispenser port 37; and creme rinse compartment 18 is provided with a creme rinse dispenser port 38.
Flow of fluids to be dispensed through each of these ports is controlled by an appropriate valve. Egress from port 36 is controlled by soap dispenser valve 40; egress from port 37 is controlled by shampoo dispenser valve 41; and egress from port 38 is controlled by creme rinse dispenser valve 42. The illustration of shampoo dispenser port 37 and valve 41 in open position and of creme rinse dispenser port 38 and valve 42 in closed position are typical. Each valve includes a partly cylindrical portion which is sealingly rotatably mounted in the bottom wall of the container 12 and is so constructed that when it is in its open position as seen to the left in FIG. 5, fluid can flow through port 37 and a central opening 43 provided in valve 41. As seen to the right in FIG. 5, when the creme rinse valve 42 is in its closed condition, it blocks creme rinse dispenser port 38 to prevent egress from creme rinse compartment 18 through valve opening 43. Many other appropriate structures could be used to control egress from ports 36, 37 and 38.
The rectilinear open face case 14 includes a top wall 44, a bottom wall 45, a first side wall 46, a second side wall 47, and a back wall 49. There is no front wall. The configuration of the case is such that each of the top, bottom and side walls will fit snugly into adjacent relationship with the corresponding wall of the rectilinear container 12.
As seen in FIGS. 2 and 3, a suction cup 50 is permanently attached to the back wall 49 of the case 14.
The configuration of the valves, and particularly the shampoo valve 41 and creme rinse valve 42 is such that when they are in the closed position, they fit entirely within the container 12. Thus, when the container is in its storage position with respect to the case, as seen in FIGS. 1 and 2, for example, the bottom wall 45 of the case 14 will prevent deliberate or accidental opening of either of the valves 41 or 42. The back wall 49 of the case prevents access to soap dispenser valve 40 when the container is in storage position in the case.
Fastening means are provided to temporarily fixedly position the container 12 and the case 14 with respect to each other in the storage position as illustrated in FIG. 2 and in the soap and water drain position as seen in FIGS. 3 and 4. In the form of the invention as shown, this means is illustrated as including a first positioning groove 54 in the resilient top, bottom and side walls around the entire outer periphery of the reilient container 12; a second storage positioning groove 56 also provided around the entire periphery of the container 12 in spaced parallel relation to the first groove 54; and a single tongue 58 extending integrally inwardly from the inner surfaces of the top, bottom and side walls of the case 14 and adapted to fit alternately in either of the grooves 54 or 56.
When the unit and the fluids in it are to be stored, the case 14 will be associated with the container 12 as seen in FIG. 2. with the tongue 58 in second positioning groove 56. When the unit is to be used for washing, the case can be affixed by suction cup 50 to a vertical side wall (for example, a bathroom tile), and the container 12 will be removed from it. Valve 40 will be opened, the sponge wet and soap squeezed out onto the sponge. After the container and sponge have been used for washing, the container will be repositioned inside of the case hanging from the bathroom wall with the tongue 58 in the first positioning groove 54 as seen in FIGS. 3 and 4, to allow liquid soap and water to drain through an opening 66 provided in the bottom wall 45 of the case.
A hanger strap 60 extends upwardly and outwardly from the top wall 44 of the case 14 and is provided with an opening 61 therethrough to receive a hanger cord by which a bather could suspend the unit 10 from a hook, or from around his neck where no smooth surfaces capable of receiving and holding a suction cup are available.
OPERATION
A method of using a portable personal liquid storage and dispensing unit made according to the invention can include first pressing the unit 10 and its suction cup 50 against a smooth area of bathroom wall adjacent a shower head, for example. Next, the container 12 can be removed from the case 14, the soap dispenser valve 40 opened, and the flexible and resilient container 12 squeezed to tend to reduce the total volume in the container. This tendency to reduce the size of the shampoo container 17 and creme rinse container 18 will cause the resilient wall 30 to flex in direction toward the liquid soap compartment 16, and deflection of the other resilient walls bounding the soap compartment 16 will combine to cause liquid soap to be dispensed through port 36 and valve 40. This liquid soap will enter the sponge 32 through the soap access opening 34 in the sponge, and when mixed with water from the shower head, will allow the sponge to be used to scrub the body of the user. When no further soap is needed or desired, valve 40 will be closed, and the container-mounted sponge can be rinsed and used to rinse the user's body. After the user's hair has been wetted, and the resilient container fitted into the wall-mounted case to cause the tongue 58 to snap into position in alignment with the first positioning groove 54, the shampoo dispenser valve 41 can be opened, and the resilient walls of the container manually deformed to develop a pressure inside of the shampoo compartment 17 which will cause shampoo to be dispensed through the port 37 and valve 41.
The user will collect this shampoo in his hand, and apply it to his head to shampoo in any usual or desired manner.
When sufficient shampoo has been dispensed, valve 41 will be closed; and when creme rinse is needed, valve 42 will be opened. Manual pressure will again be applied to the container 12 to dispense creme rinse through its dispenser port and valve onto the hand of the user.
From the time the container 14 has been snapped into position as determined by tongue 58 and the first positioning groove 54, any fluid including water or liquid soap in the area of the sponge will drain down the sides of the sponge and between the back walls 29 and 49, and will drip through the drain opening 66 in the bottom wall 45 of the case 14 to flow harmlessly down the side of the bathroom wall beneath the unit 10.
When sufficient creme rinse has been dispensed, the resilient container 12 will be moved further back against the case 14 to cause the peripheral tongue 58 to snap from the first groove 54 into the second positioning groove 56. This will move the bottom wall 45 of the case 14 into interfering relationship with the closed shampoo dispenser valve 41 and creme rinse dispenser valve 42 thus preventing them from opening accidentally or by design while the unit is in its storage condition. This movement will also cause the drain opening 66 to be moved into contacting sealing relationship with the outside surface of the bottom wall 25 of the container 12, thus preventing any further leakage of any fluids in the sponge compartment from the unit while it is stored.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A resilient bottle or container has three compartments for liquid soap, shampoo and conditioning rinse, respectively. A normally closed, openable valve controls a port in each compartment. The soap valve opens into the center of a sponge which is fastened to the bottle. The bottle can be supported on a vacuum cup on a shower wall for dispensing shampoo and conditioning rinse. On opening of any valve, manually depressing bottle, liquid is dispensed from the corresponding compartment.
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BACKGROUND OF THE INVENTION
In the formation of integrated circuits, thin films containing metal elements are often deposited on the surface of a substrate. These thin films provide conducting and ohmic contacts in the circuits and between the various devices of an integrated circuit. For example, a desired thin film might be applied to the exposed surface of a contact or a via on a semiconductor wafer with the film passing through the insulative layers on the wafer to provide plugs of conductive material for the purpose of making interconnections across the insulating layers. There are a number of different conductors and insulators which are chosen for various purposes in an integrated circuit. These may include titanium, titanium nitride, titanium tungsten alloys, tungsten, aluminum, silicon dioxide, as well as many others.
Titanium nitride is used in a variety of applications for integrated circuit fabrication. It is used as an adhesion layer for tungsten films, as a total interconnect and as a diffusion barrier. As an adhesion layer, titanium nitride offers advantages and applications where blanket tungsten is used for contact hole and via filling. The process is normally started by depositing a thin layer of a material that acts to improve adhesion between the tungsten and the underlying dielectric. Since tungsten adheres poorly to dielectric materials, a material must be used which adheres well to the dielectric and then adheres well to the tungsten. There are several materials that are suitable, but titanium nitride has several advantageous properties such as very low resistivity and a resistance to the chemistries used to etch tungsten, as well as exhibiting good adhesion to both dielectric and tungsten films.
As a barrier layer, titanium nitride also offers advantages as it serves as an impermeable barrier to silicon. It also has an activation energy higher than other materials. For example, the activation energy for copper diffusion into titanium nitride is reported to be 4.3 eV, while the activation energy from copper into most metals is on the order of 1-2 eV. There are several different methods typically used to form a layer of titanium nitride. These can include evaporation of titanium in a nitrogen atmosphere, reactive sputtering of titanium in a nitrogen/argon mixture, sputtering titanium nitride from a target in an argon atmosphere, depositing titanium and then converting it to titanium nitride in a subsequent nitridation step, or thermal chemical vapor deposition reactions employing titanium tetrachloride and ammonia.
There are many unique concerns with each of these different methods, particularly exposure to high temperatures normally related to traditional thermal chemical vapor deposition processes. At the device level of an integrated circuit, there are shallow diffusions of semi-conductor dopants which form the junctions of the electrical devices within the integrated circuits. The dopants are initially defused using heat during the diffusion step. The dopants will continue to diffuse when the integrated circuit is subjected to high temperatures during chemical vapor deposition. Temperature limitations may become even more severe if thermal chemical vapor deposition is performed after metal interconnection or wiring has been applied to the inner integrated circuit. For example, many integrated circuits utilize aluminum as an interconnection metal. However, various undesirable voids and extrusions occur in aluminum when it is subjected to high temperatures. Therefore, once interconnecting aluminum has been deposited onto an integrated circuit, the maximum temperature to which it can be exposed is approximately 500° C. and the preferred upper temperature limit is 400° C.
Two pending applications, Ser. Nos. 08/253,366 and 08/263,393, both entitled "Method and Apparatus for Producing Thin Films By Low Temperature Plasma-Enhanced Chemical Vapor Deposition Using a Rotating Susceptor Reactor" and both filed Jun. 3, 1994, describe methods and apparatuses for producing thin films by low temperature plasma enhanced chemical vapor deposition using a rotating susceptor reactor suitable to apply by chemical vapor deposition techniques a thin layer of titanium nitride. Titanium nitride, however, frequently needs further post-treatment in order to be suitable for further use.
SUMMARY OF THE INVENTION
It is the goal of the present invention to provide a low-temperature process which is compatible with aluminum already present on a wafer to establish a high-quality titanium nitride film comparable in properties to titanium nitride films deposited at very high temperatures. It is further an object of the present invention to provide a chemical vapor deposition process which provides for the annealing of titanium nitride films at temperatures below 500° C.
In accordance with the present invention, a titanium nitride film is annealed with a plasma created from a nitrogen-containing gas in a rotating susceptor reactor at a temperature less than 500° C. More particularly, the present invention provides a method of annealing titanium nitride films with an RF generated plasma formed from a nitrogen-containing gas such as ammonia at temperatures significantly less than 500° C. This method provides for a film having relatively low resistivity and relatively low chlorine content compared to films annealed at higher temperatures.
The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawing in which:
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a diagrammatic, cross-sectional view of a reactor for use in the present invention.
DETAILED DESCRIPTION
The present invention can be used on a variety of different substrates having a deposited titanium nitride film. The titanium nitride film can be deposited by any of a variety of different techniques and methods including evaporation of titanium in a nitrogen ambient, reactive sputtering of titanium in a nitrogen argon atmosphere, sputtering titanium nitride from a target, or by thermal chemical vapor deposition reactions employing titanium tetrachloride and ammonia or nitrogen. Preferred methods of forming the titanium nitride film are disclosed more particularly in two other applications, both entitled, "Method and Apparatus for Producing Thin Films By Low Temperature Plasma-Enhanced Chemical Vapor Deposition Using a Rotating Susceptor Reactor," Ser. Nos. 08/253,366 and 08/253,393, both filed Jun. 3, 1994, incorporated herein by reference.
An apparatus suitable for plasma enhanced chemical vapor deposition is shown in the FIGURE. The FIGURE shows an RF showerhead/electrode configuration which can be utilized to practice the present invention. The chemical vapor deposition (CVD) apparatus 20 includes an RF showerhead/electrode 22 biased by an RF feedline assembly 24. Plasma and reactant gases are pumped through a cylinder assembly 26 to a substrate 28 on susceptor 30. Apparatus 20 includes a housing having a housing cover 32 and includes an RF supply assembly 34, a heat pipe assembly 36 with cooling jacket 37 and associated fluid supply lines and a gas distributor cover 39 with a sealing assembly 41. A cylinder 38 made of an insulating material such as quartz surrounds the RF feed line assembly 24.
Cylinder 38 is preferably formulated out of a high quality quartz such as Quartz T08-E available from Hereaus Amersil. Quartz cylinder 38 is supported by a showerhead/electrode 22, made of a conductive metal such as Nickel-200. An annular bore 40 is formed within housing cover 32 to receive an upper end 42 of cylinder 38. O-rings 43, 44 at the interface between stepped bore 40 and cylinder 38 form a seal at the interface. At the lower end 46 of cylinder 38, an annular notch 48 in cylinder 38 receives a peripheral edge 50 of the showerhead/electrode 22. The notch 48 of cylinder 38 rests upon the peripheral edge 50 of showerhead/electrode 22. Showerhead/electrode 22 includes a stem 52 attached to RF line tubing 54, such as by a weld at 55, to form a unitary RF line 56. RF line 56 is frictionally held and supported at its top end by collar 58. The RF line, in turn, supports showerhead/electrode 22 above susceptor 30. Showerhead/electrode 22, in turn, supports the cylinder 38 within the cylinder assembly 26 by abutting against cylinder 38 at notch 48 and holding it in bore 40. The interface between showerhead/electrode peripheral edge 50 and cylinder notch 48 is sealed by a compressed O-ring 58 which is compressed between shelf 48 and a similar corresponding annular notch 60 formed in peripheral edge 50 of the showerhead/electrode 22. A plurality of gas halos or rings 62, 64 introduce reactant gases into cylinder 38.
Generally, the substrate 28 is spaced from about 0.25 to 4 inches from the showerhead/electrode 22. The distance should be such that active ions strike the substrate.
In general, reaction gases are introduced through rings 62 and 64. These pass through cylinder 38 and a plasma is generated as the gases pass through the showerhead/electrode 22. The plasma will strike the substrate 28.
Titanium nitride can be thermally deposited upon a substrate wafer with this apparatus or other well known apparatus at approximately a temperature of 450° C. For example, a layer of titanium nitride can be deposited using TiCl 4 ammonia gas (NH 3 ) and nitrogen gas (N 2 ). There are other known methods and parameters for depositing a TiN film.
The titanium nitride film is subjected to a plasma-enhanced anneal by creating a plasma from a nitrogen-containing gas such as nitrogen or ammonia, preferably using radio frequency energy, using an apparatus such as that shown in the FIGURE. In order to conduct the plasma-enhanced anneal, the susceptor temperature should be in the range from about 400° C. to about 500° C. with the reactor pressure maintained at from about 0.5 to about 10 torr, preferably 5 torr. The nitrogen-containing gas can either be ammonia or nitrogen with ammonia being preferred. The flow rate can vary relatively widely. Generally, the flow rate will be from about 1,000 to about 10,000 sccm, with about 5,000 being preferred. It is preferred to rotate susceptor 30 to improve uniformity of the plasma over the titanium nitride film. 100 rpm is adequate although a higher rotation rate may be employed.
The RF electrode power must be sufficient to establish a plasma, but does not have to be significantly higher. Accordingly, the RF power can range from at least about 100 W, with the upper limit generally being the power at which the semiconductor is destroyed. The invention works well at frequencies ranging from 450 KHz or less up to well in excess of 26 MHz.
The anneal is continued for a period of time of 15 to about 300 seconds or more with about 60 seconds generally being considered adequate.
In order to test the quality of the present invention, a titanium nitride film was deposited by thermal chemical vapor deposition using titanium tetrachloride ammonia and nitrogen as the reacting gases. The reaction conditions are given in Table 1.
TABLE No. 1______________________________________TiCL.sub.4 (SCCM) 10NH.sub.3 (SCCM) 100N.sub.2 (SCCM) 5000REACTION CHAMBER PRESSURE (TORR) 20SUSCEPTOR ROTATION RATE (RPM) 100SUBSTRATE TEMP. (°C.) 450______________________________________
This was then annealed with a plasma anneal. The ammonia flow rate was 5,000 sccm, RF power setting 750 watts at KHz, pressure 5 torr, and rotation rate 100 rpm for 120 seconds. The susceptor temperature was maintained at 467° C., providing a wafer temperature of 450° C., which produced a film having a resistivity of 363 micro ohm-centimeters and a chlorine content of 4.5%. A similar film thermally annealed under the conditions set forth in Table 2 produced a film having a resistivity of over 1,000 micro-ohm centimeters and a chlorine content of 5.0%.
TABLE No. 2______________________________________NH.sub.3 (SCCM) 5000REACTION CHAMBER PRESSURE (TORR) 20SUSCEPTOR ROTATION RATE (RPM) 100SUBSTRATE TEMP. (°C.) 450(NO PLASMA)______________________________________
The resistivity of films annealed in this manner generally exceed 1000 μΩ-cm with chlorine contents of at least 5.0%.
Thus, by employing the present invention, an improved film is formed which has a resistivity lower than thermally annealed films and a chlorine content less than thermally annealed films. At the same time, the temperature is maintained at less than 500° C. which makes this suitable for integrated circuits having aluminum layers, improving the ability of the chemical vapor deposited titanium nitride films to be employed in integrated circuits. This significantly improves the overall utility of chemical vapor deposited titanium nitride films.
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A titanium nitride film is annealed at a temperature less than 500° C. by subjecting said titanium nitride film to an RF created plasma generated from a nitrogen-containing gas in a rotating susceptor reactor. The formed film is comparable to a thin film annealed at significantly higher temperatures, making this process useful for integrated circuits containing aluminum elements.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Application No. 60/275,613, filed Mar. 14, 2001.
BACKGROUND OF THE INVENTION
[0002] Communication networks are increasingly becoming critical resources. In-depth understanding of the communication networks' behavior and what the physical and application flows that are crossing network devices is imperative in order for the communication networks to provide good quality of service to network service customers.
[0003] A communication network may consist, in part, of an enterprise network. An enterprise network typically includes geographically dispersed devices under the control of a particular organization. It may consist of different types of networks operating together as well as different computer systems. As such enterprise networks are getting larger and more complex, analyzing the performance or flows of these networks is a challenging task. This is due, in part, to the substantial amount of data an operator must review for such an analysis.
[0004] The present invention is directed to improvements in and analyzing performance and flow for communication networks.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a method and system of analyzing collected performance and flow information for networks.
[0006] In accordance with one aspect of the invention there is disclosed a system and method for visually representing performance and flow analysis of a communication network having devices connected by links. The system includes a first memory for storing a graphical representation of the communication network and showing the devices connected by links and a second memory storing data representing performance and flows in the communication network. A processing system is operatively connected to the first and the second memory and to a display. The processing system selectively maps the data on the graphical representation of the communication network by varying visual characteristics of the devices and the links for viewing on the display.
[0007] In accordance with another aspect of the invention a system and method is provided for mapping performance and flow analysis of a communication network having devices connected by links. The system includes a first memory for storing a graphical representation of the communication network and showing the devices connected by links. A second memory stores data representing performance and flows in the communication network. A third memory stores a plurality of symbols representing different devices and a plurality of edges representing links. Processing means selectively map the data on the graphical representation of the communication network by varying visual characteristics of the symbols and the edges responsive to the performance and flows in the communication network to build a graphical display
[0008] Further aspects and advantages of the invention will be readily apparent from the specification and from the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram of a system for performing performance and flow analysis for a network;
[0010] FIG. 2 is a graphical representation of how network elements are defined in a network topology;
[0011] FIG. 3 is a graphical representation of how the network elements of FIG. 2 are illustrated in a display system in accordance with the invention;
[0012] FIG. 4 is a graphical representation of a network topology;
[0013] FIG. 5 illustrates a display generated in accordance with the invention for illustrating performance and flow for the topology of FIG. 4 ;
[0014] FIGS. 6-9 illustrate mapping techniques for representing metrics for different types of information in accordance with the invention;
[0015] FIG. 10 is a graphical representation, similar to FIG. 3 , representing bidirectional flows between two devices;
[0016] FIG. 11 is an exemplary display of bidirectional flows between two devices;
[0017] FIG. 12 is a graphical representation of a network topology for a view usage case in accordance with the invention;
[0018] FIG. 13 is an illustration of a display for the topology of FIG. 12 for illustrating a flow/volume view usage case;
[0019] FIG. 14 is an illustration of a display for the topology of FIG. 12 for illustrating a flow/congestion view usage case;
[0020] FIG. 15 is a generalized representation of a database for storing topology and statistical information used in the method and system of the present invention;
[0021] FIG. 16 is a flow diagram illustrating collection and storage of data for building the database of FIG. 15 ;
[0022] FIG. 17 is a flow diagram illustrating a visualization program algorithm in accordance with the invention;
[0023] FIG. 18 is a graphical representation of a portion of the topology for illustrating operation of the visualization program of FIG. 17 ; and
[0024] FIG. 19 is a display generated by the visualization program of FIG. 17 using the topology of FIG. 18 .
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring initially to FIG. 1 , a performance and flow analysis system 20 operates in connection with a communication network 22 . The communication network 22 carries information between remote sites or computers. The information may consist of voice, video, files, electronic mail, etc. In the illustrated embodiment of the invention, the network 22 comprises a “packet” or “connectionless” communication model. The system 20 is intended to manage enterprise networks. However, it is also suitable for management service provides (MSPs) that manage a customer's networks.
[0026] The present invention relates particularly to “visualization” software operating in the network management system 20 for the visualization of peformance and data flows on the communication network 22 . In the illustrated embodiment of the invention, the network management system 20 includes a dedicated management network 24 for gathering information from the communication network 22 . A server 26 is connected to the management network 24 . The server 26 operates in accordance with the visualization software, discussed above, A memory 28 and display 30 are operatively connected to the server 26 . The memory 28 may consist of any type of memory, including ROM memory, RAM memory, fixed disk drives and removable disk drives, and the like. The memory 28 stores the visualization software and the collected information in the form of a database, as described below. As is apparent, the memory 28 may include plural discrete memory devices. Also, individual memory devices can be considered as equivalent to separate memory devices relative to the specific data stored therein.
[0027] As will be apparent, the management network 24 may take any known form and the server 26 may be an integral component of the management network 24 . However, the server 26 is not intended to be a node in the communication network 22 as it hosts the visualization software for management purposes only.
[0028] The visualization software enables monitoring of information flows in real time or deferred time. Visualization of traffic is enabled over a specific time span to quickly pinpoint and understand cause of problems which may arrive periodically, such as, for example, bottlenecks, application slowdowns, etc. As such, the visualization software provides complete visibility of the flows and the evolution of the flows. This is done using physical mapping of the network for visualizing and understanding the complex exchange patterns between applications and users.
[0029] Referring to FIG. 2 , network devices A and B can be graphically represented as nodes 32 . Network interfaces 34 associated with each node 32 are interconnected via a link 36 . Network devices 32 can generally be classified as infrastructure devices, such as routers or switches, or the like, which are used for forwarding packets. The network devices 32 may also include terminal (LEAF) devices, such as servers, personal computers (PCs), work stations, printers, etc., that provide information to or consume information from other devices. The links 36 are mainly characterized by their technology, such as Ethernet, ATM, etc., and their transmission speed which is usually represented in bits/second. The links 36 link network devices 32 through the network interfaces 34 with one network interface 34 on each side of the link 36 . In accordance with the invention, the network management system 20 displays the network elements shown in FIG. 2 in the form illustrated in FIG. 3 . Particularly, the device nodes 32 are shown connected via a graph edge 38 . The edge 38 , which also may be referred to as an “arc”, is the chart of a link 36 which interconnects two network node devices. Thus, a link 36 is an object of the network, which is graphically displayed by an edge 38 . The network interfaces 34 are hidden on the visual display.
[0030] Packet networks divide information into several smaller packets. These packets are then handled independently by network devices. The Internet Protocol (IP) communication protocol is a typical packet-oriented protocol. The network 22 in FIG. 1 is made up of a large number of infrastructure devices, such as switches or routers, that forward each packet in a required direction depending on a final delivery address. The success of a network is its ability to handle large amounts of information and to connect together virtually unlimited numbers of users. Network performance management in accordance with the invention is based on the periodical collection of local metrics or on traffic simulation. The metrics are related to a specific device or interface.
[0031] For effective network management, it is necessary to choose a set of metrics that will characterize the network's ability to transmit the flow of information that is submitted to it and qualify the type of traffic (for example per protocol or per application, and per direction of traffic). Examples of the most frequently used metrics for performance and flow analysis include;
input and output throughput of device interfaces, information loss rate per device and per interface, overrunning of internal device resources (processors, memories, queues . . . ), etc, Per Network protocol throughput (IP/IPX/ . . . ), Per Application protocol throughput (HTTP/SMTP/NNTP/SAP/Oracle . . . ), etc.
[0034] The analysis of performance and flows require the processing of large amounts of collected data samples. Several hundred samples up to several hundreds of thousands of samples only represent an instantaneous snapshot of a network state, depending on the size of the network, and on its complexity. Furthermore, having a history of several sample periods is necessary to illustrate the dynamic nature of a network, and of its evolution. The present invention provides a specific and efficient presentation of the information in order to understand the complex system that the communication network represents.
[0035] The network management system 20 , using samples of information, makes a snapshot of the network 22 and maps user-chosen metric values on a graphic representation of the physical network topology. Device-related metrics are mapped over the graph device nodes 32 while interface-related metrics are mapped over the graph edges 38 . In accordance with the invention, the network management system 20 uses a graphic representation of topology of the network 22 , techniques for representing metrics over the graph element, referred to herein as “mappings”, automatic association methods between metrics and mappings, and an ergonomic and efficient presentation system, referred to herein as “views”, that display only a subset of all available metrics.
[0036] Referring to FIG. 4 , a classical graphical representation of the topology of a network 100 is illustrated. The network 100 includes two infrastructure devices in the form of switches 102 and 104 connected to LEAF devices in the form of PCs 105 - 112 . Node devices are represented by symbols. Different symbols are drawn depending on the device type and on the services the device provides. These services may include routing services, switching services, VLAN (Virtual Local Area Network) service, etc. In order to be compared, the node devices occupy approximately the same area on a visual display. Links are represented as connections between devices. An example is the line 114 between the PC 107 and the switch 102 . The links have speeds that can vary from several kilobits per second to gigabits per second. The size of the link reflects the nominal speed of the link in the classical representation. Particularly, the thicker the line, the faster the link.
[0037] The present invention provides dynamic visual representation of a network. This is done to represent network load along with network resources used. To do so, it is necessary to choose a few metrics out of the set of available metrics. These metrics may include, for example, the device load (number of packets per second handled by the device), the link throughput (bits per second) for each direction, and the link load (for example, a percentile of its nominal throughput). FIG. 5 illustrates mapping of the metrics in accordance with the invention for a network having a topology as shown in FIG. 4 . As is apparent, the node devices 102 and 104 have different sizes when compared to the representation of FIG. 4 , and the links are displayed as bidirectional arrows. Particularly, the size of each infrastructure element depends on the number of packets that go through the element. In the illustration of FIG. 4 , the switch 104 carries more packets than the switch 102 resulting in the larger size. Bidirectional arrows have a different thickness and a different contact point. The thickness and contact points depend on the throughput of each direction. In the illustration of FIG. 5 , it is apparent that there is a large flow of information going from the PC 107 through the switch 102 and then to the PC 108 . This traffic is far greater than the traffic involving the other PCs 105 , 106 and 109 - 112 . The color of the link also depends on the link utilization rate. In the illustration of FIG. 5 this is represented by the darker color for the transfer from the PC 107 to the PC 108 as it requires more link resources than all the other links in FIG. 5 .
[0038] The mappings, i.e., techniques for representing metrics, are used to graphically represent different types of information. The mappings allow a user to visually and quickly evaluate a metric (for example, see at a glance that a device load is near the device saturation) and compare several metrics of the same type (for example all the throughput on a network). The following describes several mappings that could be used. As is apparent, not all possible mappings are described herein.
[0039] Symbol size variation can be used for mapping symbols for node devices as illustrated in FIG. 6 . Particularly, the size of the symbol can vary from a smaller size, as shown to the left of the arrow, and be increased to a larger size, as shown to the right of the arrow. The higher the metric value, the larger the size of the node on the screen. Similarly, symbol color variation can be used by applying a color transparency level on the symbol. The higher the metric value, the higher the color level. A combination of this kind of mapping can be used with other mappings such as symbol size.
[0040] FIGS. 7-9 illustrate mapping symbols for links. Particularly, FIG. 7 illustrates link thickness variation. The higher the metric value, the thicker the link. FIG. 8 illustrates bidirectional thickness variation. This mapping simultaneously represents two metrics of the same type. The higher the metric value, the larger the associated arrow. Also, the contact point of the arrows changes according to the relative metric values in the two directions. FIG. 9 illustrates link layer thickness variation. This mapping represents simultaneously several metrics of the same type. The higher the metric value, the thicker the associated layer. Line color variation or bidirectional color variation may also be used with mapping symbols for links. This is done by applying a color transparency on the link. The higher the metric value, the higher the color level on the link or on the associated arrow.
[0041] In the illustrated embodiment of the invention, several mappings are general purpose mappings as they can be used very frequently and applied to a large number of metrics. These include size variation, thickness variation and color variation which are well suited for the visualization of the metrics such as load, volumes and rates, or the like. For example, the CPU load of a device, a link throughput, the utilization rate of a device or of a link, or the collision rate of an Ethernet link. Other mappings better fit other situations. For example, bidirectional arrows are well suited for oriented metrics. For example, flows going into or out of a device, errors detected on incoming packets, or errors detected on outgoing packets. Color layers are well suited for distribution of homogeneous metrics. For example, visualization of traffic on a link, per communication protocol, per application or per VLAN, or distribution of the traffic on a link per computer contributing to this traffic.
[0042] In order to provide a complete visualization technique, it is necessary to handle special situations. These include:
[0043] Representation of an “in range” value: a value greater or equal to a minimum value and, lower or equal to a maximum value (These values must be user definable). Representation of a value lower than the minimum value (out of range value). Representation of a value greater than the maximum value (out of range value). Representation of a missing value. This is a very frequent situation, often due to an unreachable or out of order device due to network or instrumentation problems.
[0044] For the first case (in range value) the “mapping” must represent linearly the metric value.
[0045] For the other cases, this can be qualified as “remarkable”, the mapping must define for each situation a representation that allows to distinguish very easily this special value from an “in range” value.
[0046] The following table shows the various representations for each situation of the Mappings described above:
Missing Value < [min >= Value > Mapping value minimum value <= max] maximum Symbol Dashed Very Symbol size “Exploded” size corners small linearly Symbol symbol modified. Symbol Transparent User Color User color defined transparency defined color level applied color linearly Link Standard Thickness Thickness Maximum thickness thickness set to 1 linearly thickness + Dashed line pixel modified Dashed borders Link Transparent User Color User color defined transparency defined color level applied color linearly Bi-di- Standard Thickness Thickness Maximum rectional thickness set to 1 linearly thickness + arrow Dashed pixel modified Dashed thickness arrow borders
[0047] The symbols and edges used in the mapping technique are stored in the memory 28 . When metrics are selected to build a display the appropriate symbols or edges are selected from the memory in accordance with the metrics to be analyzed, as will be apparent.
[0048] For association methods between metrics and mappings, metrics can be collected in various manners. Among these are real time counters polling from the devices, information pushed from devices or to the system, or a query from a database, the database being fed by a collection process. Metrics are always associated with instrumented objects. An instrumented object is an object able to provide measurements. Network devices and network device interfaces are objects which can be instrumented. Often, a link is not an object which can be instrumented. Therefore, a metric is often not directly associated with a link. FIG. 2 , discussed above, shows the real elements involved in a connection between devices. The presentation system representation is shown in FIG. 3 . In order to facilitate presentation of metrics on an edge, the presentation technique herein defines rules that will associate these metrics with an edge:
that are directly related to the edge when direct edge metrics are available, or that are not directly related to the edge when direct edge metrics are not available, and relevant metrics are available elsewhere.
[0051] The visualization software includes a metric/mapping association system. This system is in charge of finding all relevant metrics for each type of presented objects (nodes/edge) from the set of all available metrics. The system also applies rules to select the best metric when several choices are available. In certain cases, most notably edges, the system hides the metric choice complexity, thus making it seem to the user that all metrics are directly “collected” from the presented object.
[0052] FIG. 10 illustrates an example where metrics are gathered from ends of the edge. The available metrics are the input and output throughput for each device 32 . This information comes from the device interfaces 34 . In the illustration, they are named “A.in”, “A.out”, “B.in” and “B.out”. Normally, A.in provides the same values of B.out, and A.out provides the same values as B.in. Representing the throughput going from A and B (named “A.O” and “B.O”) can be done in four ways:
A.O=A.out, B.O=B.out (metrics issued from two ends) A.O=A.out, B.O=A.in (metrics issued from only one end: A) A.O=B.in, B.O=B.out (metrics issued from only one end: B) A.O=B.in, B.O=A.in (metrics issued from the two ends, but inverted)
An example is illustrated in FIG. 11 .
[0054] In certain cases, metrics are only available at one end of an edge. This reduces the number of possible choices. Among others, possible cases include only one device being instrumented. In this case, the only choice is [A.O=A.out, B.O=A.in], or [A.O=B.in, B.O=B.out] depending on the instrumented device. Another possible case is that there is a missing metric on one side. For example, B.out is missing. In this case, the number of choices is reduced to two, i.e., [A.O=A.out, B.O=A.in] or [A.O=B.in, B.O=A.in].
[0055] The following illustrates an example of representing a number of Ethernet collisions on an edge between two devices. This example relates to a situation where the metric available on a device interface is related to the link, although it is provided by the interface. The collision number is a metric that is usually provided by a device interface, but it represents the number of collisions detected on the media, not on the interface itself. Although this metric is provided by a device interface, it is in fact related to the edge on the graphic representation of the network. The metric/mapping association system has to associate this interface metric with the edge, or will have to choose, randomly or arbitrarily, one metric in case this metric is available on the two ends.
[0056] Every network element, such as a node or an edge, can provide dozens of metrics. Physiologically, a person is unable to perceive such a great amount of information at the same time, for each node and edge representing a network. Assuming a person is able to perceive two to three different metrics per element type, there are a maximum of six different metrics for a network representation made of two types of elements, namely nodes and edges. The visualization software described herein applies a “view” principle to the presentation and mapping techniques described. A view is a subset of metrics per element type. This subset is applied to the graph that represents the network and is a subset for nodes, typically up to two, and a subset for edges, typically up to three. Each metric is applied to all the elements of the same type. For example, if the CPU utilization metric is chosen for nodes, then all the nodes will display their CPU utilization metric. The view principle allows the user to focus on one or several aspects of the network. For example, flow analysis, congestion analysis or state analysis. Flow analysis considers the kind of traffic, the communication protocols used, the applications used and the volumes being transferred. Congestion analysis considers the bottlenecks, the resource usage and collisions. The state analysis considers which devices or links are down, the availability of the devices, and the most frequently faulty devices. Alternative types of use might also be used.
[0057] FIG. 12 illustrates a network to be analyzed for a flow/volume view usage case. This view is based on three metrics. Device workload is mapped on device size. The higher number of packets across a device, the larger the device. Input and output throughput are mapped on edges, represented by bidirectional arrows. The higher the volume in one direction, the thicker the arrow. The total throughput on edges is represented by a color variation. The greater the traffic, the more color in the edge. FIG. 12 illustrates the topology for a network 120 to be analyzed for the flow/volume usage case. FIG. 13 illustrates a visualization display generated using the system 20 of FIG. 1 for the network 120 of FIG. 12 under certain conditions. Particularly, this view of FIG. 13 shows the current flows between devices and particularly pinpoints the greatest flow which is going from a device 122 to a device 124 . This flow is through several other devices.
[0058] For a flow/congestion view usage case, the view is based on a different set of metrics. Device workload is mapped on device size. The higher number of packets across a device, the larger the device. Input and output throughput are mapped on edges, represented by bidirectional arrows. The higher the volume in one direction, the thicker the arrow. The link's usage rate is mapped on edges and represented by a color variation. The more congested the link, the more color in the edge.
[0059] FIG. 14 illustrates an example of a flow/congestion view usage case for the network 120 . This view gives the user a new vision of the phenomenon. In fact, the link between the central device 126 and the device 124 has a higher transfer rate than the others. This means that although the transfer is great, the link is not overloaded. But the other links are near saturation. One can imagine that the transfer rate is limited by the links between the device 122 and the central device 126 .
[0060] Other views such as views expressing the correlation between collision rate and response time or collision rate and volume, would provide valuable information for understanding the behavior of the network and analyzing it.
[0061] Referring to FIG. 15 , a database 40 is represented graphically. The database 40 is stored in the memory 28 of FIG. 1 , as described above. Among the information stored in the database 40 are topology representations 42 and metric samples in the form of statistics 44 . These statistics are illustrated in three-dimensional form as “Ine” (representing instrumented network elements), metrics and time. A snapshot of these statistics represents a plane cut through the three-dimensional representation at a given time to illustrate the metrics at that time for all of the Ine's.
[0062] Referring to FIG. 16 , a flow diagram illustrates a program implemented in the server 26 of FIG. 1 for building the database 40 . The program begins at a block 46 where a network is defined. A network is defined by identifying the node devices 32 and edges 38 that make up the network to provide the network topology 42 , see FIG. 15 . The topology 42 is stored at a block 48 . As is apparent, the database 40 may store numerous different network topologies. Thereafter, a decision block 50 determines if it is necessary to update the database statistics 48 . The update is initiated at the appropriate time based on the techniques being used for collecting metrics, as discussed above. The program continues to loop about the block 50 until it is necessary to update the database. When an update is to occur, then the Ine's are polled at a block 52 , in one embodiment. The collected metrics are then stored at a block 54 and the program returns to the decision block 50 . The flow diagram of FIG. 16 will vary according to the particular collection process being used, as will be apparent to those skilled in the art.
[0063] Referring to FIG. 17 , a flow diagram illustrates operation of the visualization program for performance and flow analysis for a communication network. The program begins at a block 60 where the user selects a topology to be analyzed and a part of the topology, if necessary. The server 26 accesses the topology from the database 40 , see FIG. 15 . At a block 62 the user selects a view. The system 20 uses the view system in order to build a list of all metrics that could fulfill requirements. Depending on a previous list, and a set of elements that are instrumented, the system applies the rules defined in the metric/mapping association system, described above, to select the best available metrics. These are the metrics defined by the view or alternative metrics when the ideal metric is not available. At a block 64 the user selects the time for analysis. The time may be a specific time or date or may be an interval of time for analysis. The system 20 queries the statistics database 44 at a block 66 to retrieve the metric samples at the selected time. At a block 68 the system 20 sets scales to be used. For each type of metric the minimum and maximum values are searched to set the scales. For each type of metric the highest value of the scale is set to the maximum sample value found over the specified interval and the lowest value of the scale is set to the minimum sample value found.
[0064] Thereafter, a display is built at a block 70 . The display is built using the selected topology and the mapping techniques for representing metrics, discussed above. This is done by using the correct mapping and applying the rules for the particular mapping. The display is then viewed at a block 72 on the display 30 , see FIG. 1 .
[0065] An example of the operation of the flow diagram of FIG. 17 is now described with respect to FIGS. 18 and 19 . FIG. 18 shows a topology representation which could be selected at the block 60 . In this topology there are four network devices 74 , 75 , 76 and 77 . These devices are connected by various links, as shown. At the block 62 , the user selects a view that will display traffic per VLAN. VLANs are logical networks that share a same physical network. VLANs are identified by numbers in the range [1 . . . 1024]. A VLAN number is comparable to a link metric. This view specifies the ideal metrics that are required and the alternative metrics that could provide the same information. For each device 74 - 77 the workload metric (the number of packets across the device) is the ideal metric. There is no alternate metric. On each link, the input and output throughput metrics are the ideal metrics. Alternative metrics are described above relative to association methods between metrics and mappings. For each link the VLAN number metric is an ideal metric. This metric should be available from any one of the two ends of the link. An alternative metric is the VLAN number metric from the opposite end of the link. The system 20 compares the ideal metric list with what is available from the selected elements that make the selected type topology. Alternate metric choice methods are applied when ideal metrics are not available. The system builds the list of available metrics for each network element.
[0066] After the user selects the time or interval for analysis, the minimum and maximum values are searched over the specified interval in order to set the scales at the block 68 . On this topology, four devices 74 - 77 provide the workload metric. The query gets the following samples (one per each five minutes between 2 a.m. and 2:30 a.m.):
Device/Date/Value 2:00 AM 2:05 AM 2:10 AM 2:15 AM 2:20 AM 2:25 AM Device 74 50 pp/s 200 pp/s 30 pp/s 210 pp/s 25 pp/s 35 pp/s Device 75 20 pp/s 40 pp/s 28 pp/s 30 pp/s 40 pp/s 40 pp/s Device 76 45 pp/s 100 pp/s 110 pp/s 40 pp/s 80 pp/s 35 pp/s Device 77 50 pp/s 60 pp/s 40 pp/s 35 pp/s 25 pp/s 10 pp/s
[0067] The lowest value of the scale for the workload type of metric is set to 10 pp/s per second, as determined by device 77 at 2:25 a.m. The highest value of the scale is set to 210 pp/s per second, as determined by the device 74 at 2:15 a.m. The same processes are run for the input and output throughput and VLAN number metrics.
[0068] Thereafter, the view system is used to get from the view how to represent the metrics. This view specifies to represent the workload metric as a node size variation, the input and output throughput metric as bidirectional arrows with variable thickness, and the VLAN number metric as link color, one color per VLAN number. The mapping rules are applied to represent sample values according to the specified mappings as illustrated in FIG. 19 . Particularly, FIG. 19 illustrates the results at 2:15 a.m. The Device 74 has the highest workload (210 pp/s) and the other devices 75 , 76 , 77 have a similar and rather low relative workload (30, 40 and 35 pp/s). One can visually see in FIG. 19 that Device 74 is the most used device on this network and that the other devices have a similar load relative to one another. The links are colored according to their VLAN number. Each distinct VLAN is assigned a different color. In the illustrated embodiment of the invention, five different VLANs cross the Device 74 and are helpful in analyzing the traffic distribution per VLAN. Bidirectional arrow thickness represents the input and output throughput for each link. The thicker the arrow, the greater the traffic in that direction.
[0069] The present invention has been described with respect to flowcharts and block diagrams. It will be understood that each block of the flowchart and block diagrams can be implemented by computer program instructions. These program instructions may be provided to a processor to produce a machine, such that the instructions which execute on the processor create means for implementing the functions specified in the blocks. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer implemented process such that the instructions which execute on the processor provide steps for implementing the functions specified in the blocks. Accordingly, the illustrations support combinations of means for performing a specified function and combinations of steps for performing the specified functions. It will also be understood that each block and combination of blocks can be implemented by special purpose hardware-based systems which perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.
[0070] Thus, in accordance with the invention there is provided a new and effective way of analyzing collected performance and flow information for large networks, allowing a user to understand what's happening on a network.
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A system and method are used for visually representing performance and flow analysis of a communication network having devices connected by links. The system includes a first memory for storing a graphical representation of the communication network and showing the devices connected by links and a second memory storing data representing performance and flows in the communication network. A processing system is operatively connected to the first and the second memory and to a display. The processing system selectively maps the data on the graphical representation of the communication network by varying visual characteristics of the devices and the links for viewing on the display.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Appl. No. 61/947,059 filed Mar. 3, 2014, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to waterproof pump enclosures, and more particularly to a waterproof pump enclosure and system including the same for pumping fuel oil from below history flood levels.
[0004] 2. Description of Related Art
[0005] When Hurricane Sandy hit New York City in October 2012 many of the basements in lower Manhattan were flooded by seawater. New York City basements typically house the boilers, emergency generators, and their diesel fueling systems. Most of the hospitals in Manhattan lost grid power, lost emergency back-up power, and had to be evacuated. For example, Bellevue Hospital had emergency generators above the Sandy flood line, but the fueling system for the generators was in the basement and was incapacitated by flooding.
[0006] One option for overcoming these difficulties is to install new pumps above the flood line, but this solution is not practical for all locations. For example, in New York City most of the oil tanks are in the basements of the buildings, and there is not sufficient room to relocate the tanks to location on or within the buildings that would be above the flood line. Pumps cannot be elevated without raising the tanks because positive displacement gear pumps are limited by the amount of suction they can generate to pull oil out of tanks. Positive displacement pumps can generally only pull oil up 12-15 feet. Furthermore, alternatives, such as submersible pumps located in the oil tanks may not be approved for use in all locations.
[0007] In addition, there are also problems associated with a system in which submersible pumps are used to pump oil out of the tanks to positive displacement pumps that would supply enough pressure to push oil up many stories to where boilers and diesel generators are sometimes located. Submersible pumps also do not generate enough head pressure to push oil above two or three stories. Additionally, submersible pump-positive displacement pump systems are difficult to control, risk over-pressuring the inlet of the positive displacement pumps, and are at increased risk of causing a fuel oil spill.
[0008] Therefore, what is needed is a means for installing positive displacement pumps in their usual location in the basements at the same level as the oil tanks to prevent suction lift problems, and then having pump accessories such as gauges, pressure relief valves, flow switches, and pump controls could be located above the flood level.
SUMMARY OF THE INVENTION
[0009] The present invention is designed to overcome the above noted limitations that are attendant upon the use of conventional pumps and, toward this end, it contemplates the provision of a novel waterproof pump enclosure and system including the same.
[0010] It is an object of the present invention to provide a positive displacement fuel oil pump in a waterproof enclosure.
[0011] It is a further object of the present invention to provide a discriminating leak detector to indicate the presence of oil or water in the interior of the enclosure.
[0012] It is another object of the present invention to provide flexible stainless steel hoses with unions to connect the supply and suction sides of the pump to waterproof bulkhead fittings welded to the pump enclosure.
[0013] It is yet another object of the present invention to provide a sliding tray to allow the oil pump and motor to be slid partially out of the enclosure for maintenance.
[0014] It is still another object of the present invention to provide waterproof conduit connections for the pump motor leads and the leak detector wires.
[0015] It is yet another object of the present invention to provide a heavy duty gasketed manhole cover to provide a waterproof seal when tightened down, and access to the interior of the pump enclosure when opened up.
[0016] It is still another object of the present invention to provide a pump enclosure for applications were fuel oil pumps cannot be installed above historic flood levels due to suction lift constraints.
[0017] It is a further object of the present invention to provide a pump enclosure that is designed to withstand seawater inundation, and continue supplying fuel, for example diesel fuel, to critical generators and boilers.
[0018] It is yet another object of the present invention to provide a pump enclosure that shows only negligible temperature rise inside the enclosure when the pumps are under load.
[0019] It is still another object of the present invention to provide a pump enclosure that allows for pump accessories, such as pump control panels, motor starters, strainers, gauges and switches.
[0020] It has now been found that the foregoing and related objects can be readily attained in an oil pump and motor assembly assembled in an epoxy enamel-coated carbon steel waterproof enclosure with external threaded connections for pump suction and discharge. The base-mounted motor can be directly connected to a flexible coupling to a bi-rotational internal gear pump, having self-adjusting mechanical seals and cast iron housing. The pump and motor assembly can be mounted on a sliding steel base for easy access. Stainless steel flex hoses can be used to connect pump suction and discharge to coupling welded to the pump enclosure. A discriminating leak detector can be installed at the low point of the pump enclosure to detect and annunciate the presence of oil and/or water. Electrical connections can include sealed conduit and wire pigtails for termination above expected high water and/or flood levels. Pump and motor assemblies can be any suitable pump and motor assemblies available from Preferred Utilities Manufacturing Corp. of Danbury, Conn. that are suitable for No. 2 fuel oil, No. 4 fuel oil and or diesel fuel.
[0021] The pump enclosures may be installed in any building, for example high rise buildings, that are located in low-lying areas and/or areas prone to flooding. Such buildings may include hospitals, government buildings, and private buildings housing financial, high-tech, or other critical systems that typically have emergency diesel generators, but require fuel for the generators to run.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] For a fuller understanding of the nature and object of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
[0023] FIG. 1 is a schematic view of an exemplary system in which an exemplary embodiment of a waterproof pump enclosure according to the present invention may be used;
[0024] FIG. 2 is a front view of an exemplary embodiment of a waterproof pump enclosure according to the present invention;
[0025] FIG. 3 is a cross-sectional view taken along line 3 - 3 in FIG. 2 of the waterproof pump enclosure according to the present invention;
[0026] FIG. 4 is a front view of another exemplary embodiment of a waterproof pump enclosure according to the present invention, with the front cover plate shown transparently;
[0027] FIG. 5 is a cross-sectional view taken along line 5 - 5 in FIG. 4 of the waterproof pump enclosure according to the present invention;
[0028] FIG. 6 is a top plan view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0029] FIG. 7 is a front view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0030] FIG. 8 is a cross-sectional view taken along line 8 - 8 in FIG. 7 of the waterproof pump enclosure according to the present invention;
[0031] FIG. 9A is a front view of a cover assembly for the waterproof pump enclosure according to the present invention;
[0032] FIG. 9B is a side view of the cover assembly for the waterproof pump enclosure according to the present invention;
[0033] FIG. 10A is a top plan view of a mounting plate for the waterproof pump enclosure according to the present invention;
[0034] FIG. 10B is a side view of the mounting plate for the waterproof pump enclosure according to the present invention;
[0035] FIG. 11A is a top plan view of a sliding plate for the waterproof pump enclosure according to the present invention;
[0036] FIG. 11B is a side view of the sliding plate for the waterproof pump enclosure according to the present invention;
[0037] FIG. 12A is a front view of the waterproof pump enclosure with the cover assembly removed and without internal components;
[0038] FIG. 12B is a cross-sectional view taken along line 12 B- 12 B in FIG. 12A ;
[0039] FIG. 12C is an enlarged view of Section 12 C from FIG. 12B ;
[0040] FIG. 13A is a front view of an exemplary flange for the waterproof pump enclosure according to the present invention;
[0041] FIG. 13B is a side view of the exemplary flange for the waterproof pump enclosure according to the present invention;
[0042] FIG. 14A is a front view of an exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0043] FIG. 14B is a cross-sectional view taken along line 14 B- 14 B in FIG. 14A of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0044] FIG. 14C is a top plan view of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0045] FIG. 15A is a front view of an exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0046] FIG. 15B is a side view of the exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0047] FIG. 16 is a cross-sectional view of an exemplary body pipe for the waterproof pump enclosure according to the present invention;
[0048] FIG. 17A is a front view of an exemplary flange gasket for the waterproof pump enclosure according to the present invention;
[0049] FIG. 17B is a side view of the exemplary flange gasket for the waterproof pump enclosure according to the present invention;
[0050] FIG. 18 is a front view of another exemplary embodiment of a waterproof pump enclosure according to the present invention, with the front cover plate shown transparently;
[0051] FIG. 19 is a cross-sectional view taken along line 19 - 19 in FIG. 18 of the waterproof pump enclosure according to the present invention;
[0052] FIG. 20 is a top plan view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0053] FIG. 21 is a front view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0054] FIG. 22 is a cross-sectional view taken along line 22 - 22 in FIG. 21 of the waterproof pump enclosure according to the present invention;
[0055] FIG. 23A is a front view of a cover assembly for the waterproof pump enclosure according to the present invention;
[0056] FIG. 23B is a side view of the cover assembly for the waterproof pump enclosure according to the present invention;
[0057] FIG. 24A is a top plan view of a mounting plate for the waterproof pump enclosure according to the present invention;
[0058] FIG. 24B is a side view of the mounting plate for the waterproof pump enclosure according to the present invention;
[0059] FIG. 25A is a top plan view of a sliding plate for the waterproof pump enclosure according to the present invention;
[0060] FIG. 25B is a side view of the sliding plate for the waterproof pump enclosure according to the present invention;
[0061] FIG. 26A is a front view of the waterproof pump enclosure with the cover assembly removed and without internal components;
[0062] FIG. 26B is a cross-sectional view taken along line 26 B- 26 B in FIG. 26A ;
[0063] FIG. 26C is an enlarged view of Section 26 C from FIG. 26B ;
[0064] FIG. 27A is a front view of an exemplary flange for the waterproof pump enclosure according to the present invention;
[0065] FIG. 27B is a side view of the exemplary flange for the waterproof pump enclosure according to the present invention;
[0066] FIG. 28A is a front view of an exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0067] FIG. 28B is a cross-sectional view taken along line 28 B- 28 B in FIG. 28A of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0068] FIG. 28C is a top plan view of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0069] FIG. 29A is a front view of an exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0070] FIG. 29B is a side view of the exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0071] FIG. 30 is a cross-sectional view of an exemplary body pipe for the waterproof pump enclosure according to the present invention;
[0072] FIG. 31A is a front view of an exemplary flange gasket for the waterproof pump enclosure according to the present invention;
[0073] FIG. 31B is a side view of the exemplary flange gasket for the waterproof pump enclosure according to the present invention;
[0074] FIG. 32 is a front view of another exemplary embodiment of a waterproof pump enclosure according to the present invention, with the front cover plate shown transparently;
[0075] FIG. 33 is a cross-sectional view taken along line 33 - 3 in FIG. 32 of the waterproof pump enclosure according to the present invention;
[0076] FIG. 34 is a top plan view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0077] FIG. 35 is a front view of the other exemplary embodiment of the waterproof pump enclosure according to the present invention, shown transparently to show internal components;
[0078] FIG. 36 is a cross-sectional view taken along line 36 - 36 in FIG. 35 of the waterproof pump enclosure according to the present invention;
[0079] FIG. 37A is a front view of a cover assembly for the waterproof pump enclosure according to the present invention;
[0080] FIG. 37B is a side view of the cover assembly for the waterproof pump enclosure according to the present invention;
[0081] FIG. 38A is a top plan view of a mounting plate for the waterproof pump enclosure according to the present invention;
[0082] FIG. 38B is a side view of the mounting plate for the waterproof pump enclosure according to the present invention;
[0083] FIG. 39A is a top plan view of a sliding plate for the waterproof pump enclosure according to the present invention;
[0084] FIG. 39B is a side view of the sliding plate for the waterproof pump enclosure according to the present invention;
[0085] FIG. 40A is a front view of the waterproof pump enclosure with the cover assembly removed and without internal components;
[0086] FIG. 40B is a cross-sectional view taken along line 40 B- 40 B in FIG. 40A ;
[0087] FIG. 40C is an enlarged view of Section 40 C from FIG. 40B ;
[0088] FIG. 41A is a front view of an exemplary flange for the waterproof pump enclosure according to the present invention;
[0089] FIG. 41B is a side view of the exemplary flange for the waterproof pump enclosure according to the present invention;
[0090] FIG. 42A is a front view of an exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0091] FIG. 42B is a cross-sectional view taken along line 42 B- 42 B in FIG. 42A of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0092] FIG. 42C is a top plan view of the exemplary mounting bracket for the waterproof pump enclosure according to the present invention;
[0093] FIG. 43A is a front view of an exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0094] FIG. 43B is a side view of the exemplary back cover plate for the waterproof pump enclosure according to the present invention;
[0095] FIG. 44 is a cross-sectional view of an exemplary body pipe for the waterproof pump enclosure according to the present invention;
[0096] FIG. 45A is a front view of an exemplary flange gasket for the waterproof pump enclosure according to the present invention; and
[0097] FIG. 45B is a side view of the exemplary flange gasket for the waterproof pump enclosure according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0098] The present invention now will be described more fully hereinafter with reference to the accompanying figures, in which exemplary embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like reference numerals refer to like elements throughout.
[0099] Referring now to FIG. 1 , a general schematic diagram of a system in which a pump enclosure 10 according to the present invention may be employed is shown. The pump enclosure 10 may contain a suitable pump 50 , for example a light oil pump, and the pump enclosure 10 may be constructed to be substantially waterproof so that the pump enclosure 10 may be installed in a building (not shown) below the anticipated flood level. The pump enclosure 10 is connected by a suction line 30 to a tank (not shown), for example an oil tank, containing the fluid to be transported by the pump 50 , and is further connected to generators (not shown), for example emergency backup generators, and/or boilers (not shown), for example heating boilers, by a discharge line 25 so that the fluid to be transported, for example oil, can be transported by the pump 50 from the tank positioned above the anticipated flood level of the building to the generators and/or boilers positioned above the anticipated flood level of the building. The pump enclosure 10 may also be connected to a pump control panel 70 by one or more sealed electrical conduits 20 that are coupled to the pump enclosure 10 by one or more potting eyes 15 to provide for a watertight connection between the electrical conduits 20 and the pump enclosure 10 .
[0100] Referring now to FIGS. 2 and 3 , therein illustrated is an exemplary embodiment of the pump enclosure, generally indicated by reference numeral 10 , according to the present invention. The pump enclosure 10 includes a substantially cylindrical body pipe 19 that forms a hollow enclosure. The body pipe 19 may be formed from Schedule 40 pipe, or any other suitable substantially cylindrical material. The pump enclosure 10 further includes a cover plate 22 that may be removably affixed to the body pipe 19 , and a back plate 23 that may be welded to the body pipe 19 . It is understood that the cover plate 22 and the back plate 23 should be attached to the body pipe 19 so as to provide a substantially watertight hollow enclosure of the pump enclosure 10 for housing the pump 50 . The pump 50 may be supported within the hollow enclosure of the body pipe 19 by a mounting plate 27 , to which the pump 50 may be secured by one or more fasteners. The pump enclosure 10 may also include a supply inlet 14 that may be connected to a line from a tank (not shown in FIGS. 2 & 3 ), and to a flexible hose 12 that is connected to the pump 50 . The pump enclosure 10 may further include a discharge outlet 17 that is connected to a discharge line (not shown) connected to a generator and/or boiler and a flexible hose 12 (in FIG. 2 ) that is connected to the pump 50 . The supply inlet 14 and discharge outlet 17 provide for passageways through the body pipe 19 , but provide for watertight connections between the lines running to the pump enclosure 10 and the flexible hoses 12 within the pump enclosure 10 connected to the pump 50 . The pump enclosure 10 may also include one or more potting eyes 15 that provide for connection between the pump enclosure 10 and electrical wiring (not shown in FIGS. 2 and 3 ) running to the pump control panel (not shown in FIGS. 2 and 3 ) that may be positioned above the anticipated flood level of a building. The pump enclosure 10 may also include one or more mounting brackets 29 for securing mounting the pump enclosure 10 to a surface (not shown) by either welding and/or mechanical fasteners (not shown). It is understood that the pump enclosure 10 should be securely mounted to the surface so that in the event that the area surrounding the pump enclosure is inundated with water, the force of the water will not cause the pump enclosure 10 to move from its fixed position within the building.
[0101] Referring now to FIGS. 4-8 , another exemplary embodiment of a pump enclosure, generally indicated by reference numeral 110 , according to the present invention is shown. The pump enclosure 110 may include a substantially circular body pipe 119 that may be formed from epoxy-enamel painted carbon steel to form a hollow enclosure. The exemplary body pipe 119 that may be used with the pump enclosure 110 is shown by itself in FIG. 16 .
[0102] Referring now to FIGS. 4-8 , 12 A- 12 C and 13 A- 13 B, the pump enclosure 110 may also include a flange 140 formed on one end of the body pipe 119 . As shown by FIGS. 12A and 12C , the flange 140 may be positioned substantially perpendicular to the body pipe 119 so that the flange 140 provides a mounting surface for the body pipe 119 . The flange 140 may be integrally formed with the body pipe 119 , or constructed of a separate component, for example as shown in FIGS. 13A and 13B , and affixed to the body pipe 119 through suitable welding and/or adhesive. As shown in FIG. 13B , the flange 140 includes a plurality of bores 141 formed there through and positioned around the circumference of the flange 140 . The bores 141 may be positioned in any pattern or formation around the flange 140 , and it may be preferable that the bores 141 are positioned so that any fastening device as discussed below used on the flange 140 provides a substantially equal clamping pressure around the circumference of the flange 140 .
[0103] Referring now to FIGS. 4-8 , 9 A- 9 B and 17 A- 17 B, the pump enclosure 110 may also include a cover plate 122 that is configured to be secured to the flange 140 by one or more suitable fasteners, such as a bolt 153 and nut 154 combination. It is understood that any suitable fastener may be used to secure the cover plate 122 to the flange 140 , but it is preferable that the fasteners are capable of releasing the cover plate 122 from the flange 140 through appropriate removable mechanisms and/or tools so that access to the interior of the pump enclosure 110 can be gained without substantial effort or difficulty. While a bolt 153 and nut 154 combination is provided as an example of a suitable fastener, it is understood that such combination is merely exemplary and that the fasteners may also include screws that engage with threads within the bores 141 of the flange 140 . A gasket 152 , as shown in greater detail in FIGS. 17A-17B , for example a gasket made from neoprene rubber, may be placed between the cover plate 122 and flange 140 so as to provide a water tight connection between the cover plate 122 and the flange 140 so as to seal the pump enclosure 110 . The gasket 152 may include one or more bores 155 positioned around the circumference of the gasket 152 so that the fasteners 153 , 154 may be inserted through the cover plate 122 , gasket 152 and flange 140 . Preferably, the bores 155 formed through the gasket 152 are positioned for alignment with the bores 141 formed in the flange 140 and preferably the same number of bores 141 formed in the flange 140 are present in the gasket 152 . However, it is understood that additional bores 155 may be formed in the gasket 152 than those formed in the flange 140 so that alignment and installation of the gasket 152 on the flange 140 may be facilitated. Referring now more particularly to FIGS. 9A and 9B , cover plate 122 may include one or more handles 147 to facilitate removal and installation of the cover plate 122 , and may also include one or more bores 125 positioned around the circumference of the cover plate 122 so that the fasteners 153 , 154 may be inserted through the cover plate 122 , gasket 153 and flange 140 . The handles 147 may be formed from substantially U-shaped or C-shaped rod or bar, and securely affixed to the cover plate 122 . The one or more bores 125 are positioned around the cover plate 122 so that when the cover plate 122 is applied to the flange 140 the bores 141 on the flange 140 substantially align with the bores 125 on the cover plate 122 so that the fasteners 153 , 154 can secure the cover plate 122 to the flange 140 . It is understood that the bores 125 on the cover plate 122 may be the same number as the bores 141 on the flange 140 or may be greater or lesser in number depending upon the desired application.
[0104] Referring now to FIGS. 4-8 and 15 A- 15 B, the pump enclosure 110 may also include a welded rear cover 123 positioned on an end of the body pipe 119 opposite the cover plate 122 and flange 140 . The rear cover 123 may be welded onto the body pipe 119 to form a substantially watertight and/or waterproof seal, and it is understood that additional waterproofing may be applied to the joint between the rear cover 123 and the body pipe 119 in order to ensure that there is a watertight and/or waterproof seal so that the interior region of the pump enclosure 110 is at least substantially leak proof. As shown in FIG. 15A , the rear cover 123 may include one or more openings 124 that are configured and dimensioned to allow connections between the interior region of the pump enclosure 110 and items on the exterior of the pump enclosure.
[0105] Referring now to FIGS. 4-8 , 10 A- 10 B and 11 A- 11 B, the pump enclosure 110 is configured to contain a pump and motor assembly 150 , which may be light oil pumps model numbers LO-203, LO-204, LO-205 or LO-206 available from Preferred Utilities Manufacturing Corp. of Danbury, Conn. The pump and motor assembly 150 may be mounted within the pump enclosure 110 on a mounting plate 127 that is secured to the body pipe 119 . The mounting plate 127 may be secured to the body pipe 119 through welds and/or adhesives, or may be attached to the body pipe 119 by suitable brackets (not shown). The mounting plate 127 may be installed in the interior region of the pump enclosure 110 so that it forms a chord of the circle formed by the body pipe 119 . It is preferable that the mounting plate 127 is installed in the body pipe 119 so that the mounting plate 127 is substantially level relative to a surface on which the pump enclosure 110 may be installed. As shown in FIGS. 10A and 10B , the mounting plate 127 may include one or more captive nuts 162 , that may be used to secure fasteners to the mounting plate 127 . While pump and motor assembly 150 may be attached directly to the mounting plate 127 , the pump and motor assembly 150 may alternatively be attached to a sliding plate 128 that is movable relative to the mounting plate 127 so that the pump and motor assembly 150 may be at least partially removed from the pump enclosure 110 for service and/or maintenance. As shown in greater detail in FIGS. 11A and 11B , the sliding plate 128 may include side notches 139 in which the width of the sliding plate 128 is decreased over at least a portion of the sliding plate 128 . In this manner, the sliding plate 128 can be retained between fasteners 156 installed into the captive nuts 162 of the mounting plate 127 in order to keep the sliding plate 128 in the appropriate alignment within the interior region of the pump enclosure 110 . The sliding plate 128 may also include one or more bores 149 , so that the fasteners 156 can be used to secure the sliding plate 128 to the mounting plate 127 when it is not desirable for the sliding plate 128 to move relative to the mounting plate 127 . When it is desired to move the sliding plate 128 relative to the mounting plate 127 , for example for service and/or maintenance of the pump and motor assembly 150 , the fasteners 156 installed through the bores 149 can be removed so that the sliding plate 128 is movable relative to the mounting plate 127 . Suitable lubricants and/or gliding mechanisms (not shown) can be installed between the sliding plate 128 and the mounting plate 127 to ensure smooth operation of the sliding plate 128 relative to the mounting plate 127 .
[0106] Referring now to FIGS. 4-6 , the pump enclosure 110 may also include a leak detector switch 138 that is configured to detect the presence of oil and/or water within the pump enclosure 110 , and provide an indication as to their presence. The pump enclosure 110 may also include a disconnect switch 134 mounted to a disconnect bracket 142 . The pump enclosure 110 may further include a supply inlet 114 , and a discharge outlet 117 that provide passageways through the pump enclosure 110 , but also provide for watertight connections between the flexible hose 112 , which may be braided stainless steel over a Teflon core with carbon steel fittings, and an oil supply and an oil discharge lines (not shown). The supple inlet 114 and the discharge outlet 117 may be inserted through the openings 124 in the rear cover 123 , or any other suitable openings made in the pump enclosure 110 . The flexible hose 112 may be connected to the pump and motor assembly 150 by one or more nipples 145 and unions 132 in order to provide a substantially leak tight connection between the supply inlet 114 , discharge outlet 117 and the pump and motor assembly 150 . The pump enclosure 110 may also include one or more nipples 121 connected to the body pipe 119 and attached to the body pipe 119 so as to provide water tight connections between electrical conduit 120 running to the pump enclosure 110 . The electrical conduit 120 may contain wiring for distributing power to the pump and motor assembly 150 , as well as wiring for the leak sensor 138 . The pump enclosure 110 may further include a lifting lug 136 attached to the body pipe 119 in order to facilitate installation of the pump enclosure 110 .
[0107] Referring now to FIGS. 4-8 and 14 A- 14 C, the pump enclosure 110 may also include one or more mounting brackets 129 attached to an underside of the body pipe 119 . It is understood that underside is merely used for reference, and the positioning of the mounting brackets 129 are not limited to any particular location on the pump enclosure 110 . However, it is preferable that the mounting brackets 129 are positioned substantially parallel with the mounting plate 127 so that the mounting plate 127 may be substantially level with the surface on which the pump enclosure 110 may be installed. As shown in greater detail in FIGS. 14A-14C , the mounting brackets 129 include a cutout portion 165 to provide cradle for the body pipe 119 to rest in on the mounting bracket 129 . It is understood that the cutout portion 165 should have substantially the same radius as the body pipe 119 so that as much of the body pipe 119 will be in contact with the mounting bracket 129 as possible. It is further understood that the body pipe 119 may be affixed to the mounting brackets 129 through any suitable welding and/or adhesive mechanism. The mounting brackets 129 may also include one or more bores 167 through which fasteners (not shown), such as bolts, screws, nails, pins, stakes, any combination thereof or the like may be inserted in order to attach the pump enclosure 110 to the surface on which it will be mounted.
[0108] Referring now to FIGS. 18-22 , another exemplary embodiment of a pump enclosure, generally indicated by reference numeral 210 , according to the present invention is shown. The pump enclosure 210 may include a substantially circular body pipe 219 that may be formed from epoxy-enamel painted carbon steel to form a hollow enclosure. The exemplary body pipe 219 that may be used with the pump enclosure 210 is shown by itself in FIG. 30 . It is understood that while the body pipe 219 is shown with a substantially cylindrical configuration, the body pipe 219 may have any suitable shape and/or configuration in accordance with the present invention.
[0109] Referring now to FIGS. 18-22 , 26 A- 26 C and 27 A- 27 B, the pump enclosure 210 may also include a flange 240 formed on one end of the body pipe 219 . As shown by FIGS. 26B and 26C , the flange 240 may be positioned substantially perpendicular to the body pipe 219 so that the flange 240 provides a mounting surface for the body pipe 219 . The flange 240 may be integrally formed with the body pipe 219 , or constructed of a separate component, for example as shown in FIGS. 27A and 27B , and affixed to the body pipe 219 through suitable welding and/or adhesive. As shown in FIG. 27A , the flange 240 includes a plurality of bores 241 formed there through and positioned around the circumference of the flange 240 . The bores 241 may be positioned in any pattern or formation around the flange 240 , and it may be preferable that the bores 241 are positioned so that any fastening device, as discussed below, used on the flange 240 provides a substantially equal clamping pressure around the circumference of the flange 240 .
[0110] Referring now to FIGS. 18-22 , 23 A- 23 B and 31 A- 31 B, the pump enclosure 210 may also include a cover plate 222 that is configured to be secured to the flange 240 by one or more suitable fasteners, such as a bolt 253 and nut 254 combination. It is understood that any suitable fastener may be used to secure the cover plate 222 to the flange 240 , but it is preferable that the fasteners are capable of releasing the cover plate 222 from the flange 240 through appropriate removable mechanisms and/or tools so that access to the interior of the pump enclosure 210 can be gained without substantial effort or difficulty. While a bolt 253 and nut 254 combination is provided as an example of a suitable fastener, it is understood that such combination is merely exemplary and that the fasteners may also include screws that engage with threads within the bores 241 of the flange 240 . A gasket 252 , as shown in greater detail in FIGS. 31A-31B , for example a gasket made from neoprene rubber, may be placed between the cover plate 222 and flange 240 so as to provide a water tight connection between the cover plate 222 and the flange 240 so as to seal the pump enclosure 210 . The gasket 252 may include one or more bores 255 positioned around the circumference of the gasket 252 so that the fasteners 253 , 254 may be inserted through the cover plate 222 , gasket 252 and flange 240 . Preferably, the bores 255 formed through the gasket 252 are positioned for alignment with the bores 241 formed in the flange 240 , and preferably the same number of bores 241 formed in the flange 240 are present in the gasket 252 . However, it is understood that additional bores 255 may be formed in the gasket 252 than those formed in the flange 240 so that alignment and installation of the gasket 252 on the flange 240 may be facilitated. Referring now more particularly to FIGS. 23A and 23B , cover plate 222 may include one or more handles 247 to facilitate removal and installation of the cover plate 222 , and may also include one or more bores 225 positioned around the circumference of the cover plate 222 so that the fasteners 253 , 254 may be inserted through the cover plate 222 , gasket 253 and flange 240 . The handles 247 may be formed from substantially U-shaped or C-shaped rod or bar, and securely affixed to the cover plate 222 . The one or more bores 225 are positioned around the cover plate 222 so that when the cover plate 222 is applied to the flange 240 the bores 241 on the flange 240 substantially align with the bores 225 on the cover plate 222 so that the fasteners 253 , 254 can secure the cover plate 222 to the flange 240 . It is understood that the bores 225 on the cover plate 222 may be the same number as the bores 241 on the flange 240 or may be greater or lesser in number depending upon the desired application.
[0111] Referring now to FIGS. 18-22 and 29 A- 29 B, the pump enclosure 210 may also include a welded rear cover 223 positioned on an end of the body pipe 219 opposite the cover plate 222 and flange 240 . The rear cover 223 may be welded onto the body pipe 219 to form a substantially watertight and/or waterproof seal, and it is understood that additional waterproofing may be applied to the joint between the rear cover 223 and the body pipe 219 in order to ensure that there is a watertight and/or waterproof seal so that the interior region of the pump enclosure 210 is at least substantially leak proof. As shown in FIG. 29A , the rear cover 223 may include one or more openings 224 that are configured and dimensioned to allow connections between the interior region of the pump enclosure 210 and items on the exterior of the pump enclosure.
[0112] Referring now to FIGS. 18-22 , 24 A- 24 B and 25 A- 25 B, the pump enclosure 210 is configured to contain a pump and motor assembly 250 , such as model numbers LO-101E, LO-102E, LO-103E, LO-104E, LO-105E or LO-106E available from Preferred Utilities Manufacturing Corp. of Danbury, Conn. The pump and motor assembly 250 may be mounted within the pump enclosure 210 on a mounting plate 227 that is secured to the body pipe 119 . The mounting plate 227 may be secured to the body pipe 219 through welds and/or adhesives, or may be attached to the body pipe 219 by suitable brackets (not shown). The mounting plate 227 may be installed in the interior region of the pump enclosure 210 so that it forms a chord of the circle formed by the body pipe 219 . It is preferable that the mounting plate 227 is installed in the body pipe 219 so that the mounting plate 227 is substantially level relative to a surface on which the pump enclosure 210 may be installed. As shown in greater detail in FIGS. 24A and 24B , the mounting plate 227 may include one or more captive nuts 262 , that may be used to secure fasteners to the mounting plate 227 . While pump and motor assembly 250 may be attached directly to the mounting plate 227 , the pump and motor assembly 250 may alternatively be attached to a sliding plate 228 that is movable relative to the mounting plate 227 so that the pump and motor assembly 250 may be at least partially removed from the pump enclosure 210 for service and/or maintenance. As shown in greater detail in FIGS. 25A and 25B , the sliding plate 228 may include side notches 239 in which the width of the sliding plate 228 is decreased over at least a portion of the sliding plate 228 . In this manner, the sliding plate 228 can be retained between fasteners 256 installed into the captive nuts 262 of the mounting plate 227 in order to keep the sliding plate 228 in the appropriate alignment within the interior region of the pump enclosure 210 . The sliding plate 228 may also include one or more bores 249 , so that the fasteners 256 can be used to secure the sliding plate 228 to the mounting plate 227 when it is not desirable for the sliding plate 228 to move relative to the mounting plate 227 . When it is desired to move the sliding plate 228 relative to the mounting plate 227 , for example for service and/or maintenance of the pump and motor assembly 250 , the fasteners 256 installed through the bores 249 can be removed so that the sliding plate 228 is movable relative to the mounting plate 227 . Suitable lubricants and/or gliding mechanisms (not shown) can be installed between the sliding plate 228 and the mounting plate 227 to ensure smooth operation of the sliding plate 228 relative to the mounting plate 227 .
[0113] Referring now to FIGS. 18-20 , the pump enclosure 210 may also include a leak detector switch (not shown) that is configured to detect the presence of oil and/or water within the pump enclosure 210 , and provide an indication as to their presence. The pump enclosure 210 may also include a disconnect switch 234 mounted to a disconnect bracket 242 . The pump enclosure 210 may further include a supply inlet 214 , and a discharge outlet 217 that provide passageways through the pump enclosure 210 , but also provide for watertight connections between the flexible hose 212 , which may be braided stainless steel over a Teflon core with carbon steel fittings, and an oil supply and an oil discharge lines (not shown). The supple inlet 214 and the discharge outlet 217 may be inserted through the openings 224 in the rear cover 223 , or any other suitable openings made in the pump enclosure 210 . The flexible hose 212 may be connected to the pump and motor assembly 250 by one or more nipples 245 and unions 232 in order to provide a substantially leak tight connection between the supply inlet 214 , discharge outlet 217 and the pump and motor assembly 250 . The pump enclosure 210 may also include one or more nipples 221 connected to the body pipe 219 and attached to the body pipe 219 so as to provide water tight connections between electrical conduit 220 running to the pump enclosure 210 . The electrical conduit 220 may contain wiring for distributing power to the pump and motor assembly 250 , as well as wiring for the leak sensor (not shown). The pump enclosure 210 may further include a lifting lug 236 attached to the body pipe 219 in order to facilitate installation of the pump enclosure 210 .
[0114] Referring now to FIGS. 18-22 and 28 A- 28 C, the pump enclosure 210 may also include one or more mounting brackets 229 attached to an underside of the body pipe 219 . It is understood that underside is merely used for reference, and the positioning of the mounting brackets 229 are not limited to any particular location on the pump enclosure 210 . However, it is preferable that the mounting brackets 229 are positioned substantially parallel with the mounting plate 227 so that the mounting plate 227 may be substantially level with the surface on which the pump enclosure 210 may be installed. As shown in greater detail in FIGS. 28A-28C , the mounting brackets 229 include a cutout portion 265 to provide cradle for the body pipe 219 to rest in on the mounting bracket 229 . It is understood that the cutout portion 265 should have substantially the same radius as the body pipe 219 so that as much of the body pipe 219 will be in contact with the mounting bracket 229 as possible. It is further understood that the body pipe 219 may be affixed to the mounting brackets 229 through any suitable welding and/or adhesive mechanism. The mounting brackets 229 may also include one or more bores 267 through which fasteners (not shown), such as bolts, screws, nails, pins, stakes, any combination thereof or the like may be inserted in order to attach the pump enclosure 210 to the surface on which it will be mounted.
[0115] Referring now to FIGS. 32-36 , another exemplary embodiment of a pump enclosure, generally indicated by reference numeral 310 , according to the present invention is shown. The pump enclosure 310 may include a substantially circular body pipe 319 that may be formed from epoxy-enamel painted carbon steel to form a hollow enclosure. The exemplary body pipe 319 that may be used with the pump enclosure 310 is shown by itself in FIG. 44 . It is understood that while the body pipe 319 is shown with a substantially cylindrical configuration, the body pipe 319 may have any suitable shape and/or configuration in accordance with the present invention.
[0116] Referring now to FIGS. 32-36 , 40 A- 40 C and 41 A- 41 B, the pump enclosure 310 may also include a flange 340 formed on one end of the body pipe 319 . As shown by FIGS. 40B and 40C , the flange 340 may be positioned substantially perpendicular to the body pipe 319 so that the flange 340 provides a mounting surface for the body pipe 319 . The flange 340 may be integrally formed with the body pipe 319 , or constructed of a separate component, for example as shown in FIGS. 41A and 41B , and affixed to the body pipe 319 through suitable welding and/or adhesive. As shown in FIG. 41A , the flange 340 includes a plurality of bores 341 formed there through and positioned around the circumference of the flange 340 . The bores 341 may be positioned in any pattern or formation around the flange 340 , and it may be preferable that the bores 341 are positioned so that any fastening device, as discussed below, used on the flange 340 provides a substantially equal clamping pressure around the circumference of the flange 340 .
[0117] Referring now to FIGS. 32-36 , 37 A- 37 B and 45 A- 45 B, the pump enclosure 310 may also include a cover plate 322 that is configured to be secured to the flange 340 by one or more suitable fasteners, such as a bolt 353 and nut 354 combination. It is understood that any suitable fastener may be used to secure the cover plate 322 to the flange 340 , but it is preferable that the fasteners are capable of releasing the cover plate 322 from the flange 340 through appropriate removable mechanisms and/or tools so that access to the interior of the pump enclosure 310 can be gained without substantial effort or difficulty. While a bolt 353 and nut 354 combination is provided as an example of a suitable fastener, it is understood that such combination is merely exemplary and that the fasteners may also include screws that engage with threads that may be present within the bores 341 of the flange 340 . A gasket 352 , as shown in greater detail in FIGS. 45A-45B , for example a gasket made from neoprene rubber, may be placed between the cover plate 322 and flange 340 so as to provide a water tight connection between the cover plate 322 and the flange 340 so as to seal the pump enclosure 310 . The gasket 352 may include one or more bores 355 positioned around the circumference of the gasket 352 so that the fasteners 353 , 354 may be inserted through the cover plate 322 , gasket 352 and flange 340 . Preferably, the bores 355 formed through the gasket 352 are positioned for alignment with the bores 341 formed in the flange 340 , and preferably the same number of bores 341 formed in the flange 340 are present in the gasket 352 . However, it is understood that additional bores 355 may be formed in the gasket 352 than those formed in the flange 340 so that alignment and installation of the gasket 352 on the flange 340 may be facilitated. Referring now more particularly to FIGS. 37A and 37B , cover plate 322 may include one or more handles 347 to facilitate removal and installation of the cover plate 322 , and may also include one or more bores 325 positioned around the circumference of the cover plate 322 so that the fasteners 353 , 354 may be inserted through the cover plate 322 , gasket 353 and flange 340 . The handles 347 may be formed from substantially U-shaped or C-shaped rod or bar, and securely affixed to the cover plate 322 . The one or more bores 325 are positioned around the cover plate 322 so that when the cover plate 322 is applied to the flange 340 the bores 341 on the flange 340 substantially align with the bores 325 on the cover plate 322 so that the fasteners 353 , 354 can secure the cover plate 322 to the flange 340 . It is understood that the bores 325 on the cover plate 322 may be the same number as the bores 341 on the flange 340 or may be greater or lesser in number depending upon the desired application.
[0118] Referring now to FIGS. 32-36 and 43 A- 43 B, the pump enclosure 310 may also include a welded rear cover 323 positioned on an end of the body pipe 319 opposite the cover plate 322 and flange 340 . The rear cover 323 may be welded onto the body pipe 319 to form a substantially watertight and/or waterproof seal, and it is understood that additional waterproofing may be applied to the joint between the rear cover 323 and the body pipe 319 in order to ensure that there is a watertight and/or waterproof seal so that the interior region of the pump enclosure 310 is at least substantially leak proof. As shown in FIG. 43A , the rear cover 323 may include one or more openings 324 that are configured and dimensioned to allow connections between the interior region of the pump enclosure 310 and items on the exterior of the pump enclosure.
[0119] Referring now to FIGS. 32-36 , 38 A- 38 B and 39 A- 39 B, the pump enclosure 310 is configured to contain a pump and motor assembly 350 , such as model numbers LO-201 or LO-202 available from Preferred Utilities Manufacturing Corp. of Danbury, Conn. The pump and motor assembly 350 may be mounted within the pump enclosure 310 on a mounting plate 327 that is secured to the body pipe 319 . The mounting plate 327 may be secured to the body pipe 319 through welds and/or adhesives, or may be attached to the body pipe 319 by suitable brackets (not shown). The mounting plate 327 may be installed in the interior region of the pump enclosure 310 so that it forms a chord of the circle formed by the body pipe 319 . It is preferable that the mounting plate 327 is installed in the body pipe 319 so that the mounting plate 327 is substantially level relative to a surface on which the pump enclosure 310 may be installed. As shown in greater detail in FIGS. 38A and 38B , the mounting plate 327 may include one or more captive nuts 362 , that may be used to secure fasteners to the mounting plate 327 . While pump and motor assembly 350 may be attached directly to the mounting plate 327 , the pump and motor assembly 350 may alternatively be attached to a sliding plate 328 that is movable relative to the mounting plate 327 so that the pump and motor assembly 350 may be at least partially removed from the pump enclosure 310 for service and/or maintenance. As shown in greater detail in FIGS. 39A and 39B , the sliding plate 328 may include side notches 339 in which the width of the sliding plate 328 is decreased over at least a portion of the sliding plate 328 . In this manner, the sliding plate 328 can be retained between fasteners 356 installed into the captive nuts 362 of the mounting plate 327 in order to keep the sliding plate 328 in the appropriate alignment within the interior region of the pump enclosure 310 . The sliding plate 328 may also include one or more bores 349 , so that the fasteners 356 can be used to secure the sliding plate 328 to the mounting plate 327 when it is not desirable for the sliding plate 328 to move relative to the mounting plate 327 . When it is desired to move the sliding plate 328 relative to the mounting plate 327 , for example for service and/or maintenance of the pump and motor assembly 350 , the fasteners 356 installed through the bores 349 can be removed so that the sliding plate 328 is movable relative to the mounting plate 327 . Suitable lubricants and/or gliding mechanisms (not shown), e.g, Teflon or nylon strips, can be installed between the sliding plate 328 and the mounting plate 327 to ensure smooth operation of the sliding plate 328 relative to the mounting plate 327 .
[0120] Referring now to FIG. 3234 the pump enclosure 310 may also include a leak detector switch (not shown) that is configured to detect the presence of oil and/or water within the pump enclosure 310 , and provide an indication as to their presence. The pump enclosure 310 may also include a disconnect switch 334 mounted to a disconnect bracket 342 . The pump enclosure 310 may further include a supply inlet 314 , and a discharge outlet 317 that provide passageways through the pump enclosure 310 , but also provide for watertight connections between the flexible hose 312 , which may be braided stainless steel over a Teflon core with carbon steel fittings, and an oil supply and an oil discharge lines (not shown). The supple inlet 314 and the discharge outlet 317 may be inserted through the openings 324 in the rear cover 323 , or any other suitable openings made in the pump enclosure 310 . The flexible hose 312 may be connected to the pump and motor assembly 350 by one or more nipples 345 and unions 332 in order to provide a substantially leak tight connection between the supply inlet 314 , discharge outlet 317 and the pump and motor assembly 350 . The pump enclosure 310 may also include one or more nipples 321 connected to the body pipe 319 and attached to the body pipe 319 so as to provide water tight connections between electrical conduit 320 running to the pump enclosure 310 . The electrical conduit 320 may contain wiring for distributing power to the pump and motor assembly 350 , as well as wiring for the leak sensor (not shown). The pump enclosure 310 may further include a lifting lug 336 attached to the body pipe 319 in order to facilitate installation of the pump enclosure 310 .
[0121] Referring now to FIGS. 32-36 and 42 A- 42 C, the pump enclosure 310 may also include one or more mounting brackets 329 attached to an underside of the body pipe 319 . It is understood that underside is merely used for reference, and the positioning of the mounting brackets 329 are not limited to any particular location on the pump enclosure 310 . However, it is preferable that the mounting brackets 329 are positioned substantially parallel with the mounting plate 327 so that the mounting plate 327 may be substantially level with the surface on which the pump enclosure 310 may be installed. As shown in greater detail in FIGS. 42A-42C , the mounting brackets 329 include a cutout portion 365 to provide cradle for the body pipe 319 to rest in on the mounting bracket 329 . It is understood that the cutout portion 365 should have substantially the same radius as the body pipe 319 so that as much of the body pipe 319 will be in contact with the mounting bracket 329 as possible. It is further understood that the body pipe 319 may be affixed to the mounting brackets 329 through any suitable welding and/or adhesive mechanism. The mounting brackets 329 may also include one or more bores 367 through which fasteners (not shown), such as bolts, screws, nails, pins, stakes, any combination thereof or the like may be inserted in order to attach the pump enclosure 310 to the surface on which it will be mounted.
[0122] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above article without departing from the scope of this invention, it is intended that all matter contained in this disclosure or shown in the accompanying drawings, shall be interpreted, as illustrative and not in a limiting sense. It is to be understood that all of the present figures, and the accompanying narrative discussions of corresponding embodiments, do not purport to be completely rigorous treatments of the invention under consideration. It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the scope of the present invention.
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The present invention is directed to a pump and motor assembly assembled in a waterproof enclosure with external threaded connections for pump suction and discharge. The motor can be directly connected to a flexible coupling to a bi-rotational internal gear pump, having self-adjusting mechanical seals and cast iron housing. The pump and motor assembly can be mounted on a sliding base for easy access. Flex hoses can be used to connect pump suction and discharge to couplings attached to the pump enclosure. A discriminating leak detector can be installed at the low point of the pump enclosure to detect and annunciate the presence of oil and/or water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the field of variable cam timing systems. More particularly, the invention pertains to variable cam timing systems of the kind having phasers for varying the radial disposition of a camshaft relative to its drive means (sprocket or drive gear).
2. Description of Related Art
Traditionally, the camshaft (or, in a multiple camshaft engine, camshafts) of an internal combustion engine, which actuates the intake and/or exhaust valves, is connected to the crankshaft, which receives the force from the pistons, by a timing chain, belt or gear arrangement driving sprockets, pulleys or gears, respectively, on the ends of the shafts. The relative timing of the camshaft(s) and crankshaft in such a system is fixed, and must be chosen to be tailored to power or economy at a given engine speed or load condition. This is inherently a compromise, as an automobile engine does not, obviously, always run at the same speed or load, and a given car owner might desire either power or economy at different times. The demands of emissions control complicate matters further.
This has given rise to Variable Cam Timing (VCT) systems, where the timing of the valves relative to the crankshaft can be changed by altering the relative rotational positions of the camshaft(s) and crankshaft. One of the more successful systems for VCT involves using a device called a “phaser” to allow the camshaft sprocket, which is linked to the crankshaft by the timing chain, to shift angular position relative to the end of the camshaft. Typically, the phaser is a coaxial arrangement of an outer housing which forms the sprocket (or pulley or gear) and an inner rotor fixed to the camshaft. The angular position of the rotor and housing can be shifted by fluid pressure acting on pistons or vanes on the rotor inside cylinders or chambers formed in the housing.
The “vane phaser” setup is commonly used in VCT systems, and will be used in the examples in this disclosure, although it will be understood that the method of the invention will work with other forms of phasers known to the art. Butterfield and Smith, U.S. Pat. No. 5,172,659, “Differential Pressure Control System for Variable Camshaft Timing System”, assigned to BorgWarner Inc., shows a vane phaser system which uses the inherent torque reversals in the camshaft caused by the actuation of the valves to move the vane from one position to another. Fluid is led from one side of each vane to the opposing side through a valve. When the valve is open, the rotor is free to oscillate, the fluid passing freely from one side of the vane to the other. When the valve is closed, the fluid cannot flow, and the vane is held in position. By opening the valve while the torque reversal is acting to move the camshaft in the desired direction, then closing the valve, the camshaft is allowed to move, then held in place by the fluid on each side of the vane.
A number of U.S. patents show phasers which have mechanical locking mechanisms. The locking of the phaser is most often provided to prevent unwanted phase shifts during periods of high torque reversals, when the actuating force of the phaser is not sufficient to hold the selected timing, as during engine start-up, when engine oil pressure is low, reducing the available pressure to activate the phaser, the oil in the phaser may have leaked away, and the erratic engine operation can lead to dramatic forces on the cam. The following patents show different means of locking a phaser in place.
Simpson, U.S. Pat. No. 6,250,265 “Variable Valve Timing With Actuator Locking for Internal Combustion Engine”, assigned to BorgWarner Inc, shows a vane-type phaser with a locking mechanism which is released by engine oil pressure, so as to lock the phaser when engine oil pressure is low.
Trzmiel, et. al, U.S. Pat. No. 6,053,138, “Device for Hydraulic Rotational Angle Adjustment of a Shaft Relative to a Drive Wheel”, assigned to Porsche AG and Hydraulik Ring GmbH, also uses a hydraulic brake arrangement.
Muir et. al, U.S. Pat. No. 5,031,585, “Electromagnetic Brake for a Camshaft Phase Change Device”, assigned to Eaton Corporation, uses an electromagnetic clutch to lock the phaser.
Suga, et. al, U.S. Pat. No. 5,117,785, “Valve Timing Control Device for Internal Combustion Engine”, assigned to Atsugi Unisia Corporation, uses a cam or wedge locking system.
All mechanical systems have one or more resonant frequencies, where the characteristics of the system change, sometimes abruptly, with the frequency of actuation. In the case of a valve timing system for an internal combustion engine, the resonant frequencies of the camshaft, crankshaft and timing chain/belt/gears will all combine into a complex set of reactions which can lead to excessive noise or vibration at specific engine RPM.
SUMMARY OF THE INVENTION
If an engine is fitted with a VCT phaser, the resonant characteristics of the timing system will change, depending on whether the phaser is locked (i.e. the rotor and housing are acting as a unit) or unlocked (the rotor and housing can rotate independently to some extent). The method of the invention uses this alteration in characteristics to minimize the effects of resonance, by locking or unlocking the phaser as a resonant point in the engine RPM is approached.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 a shows a graph of timing chain tension vs. engine RPM for a first representative engine, with the cam phaser locked.
FIG. 1 b shows a graph of timing chain tension vs. engine RPM for a first representative engine, with the cam phaser unlocked.
FIG. 2 a shows a graph of timing chain tension vs. engine RPM for a second representative engine, with the cam phaser locked.
FIG. 2 b shows a graph of timing chain tension vs. engine RPM for a second representative engine, with the cam phaser unlocked.
FIG. 3 shows a schematic representation of an example of a cam phaser which could be used with the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 3, a vane-type cam phaser for a Variable Cam Timing (VCT) system has a housing ( 32 ), which connects to the timing drive (belt, chain or gears—not shown), and a rotor ( 31 ), which connects to the camshaft ( 30 ) of the engine. The vanes ( 36 ) of the rotor ( 31 ) can move within arcuate recesses in the housing ( 32 ), which are divided into two chambers ( 35 a )( 35 b ). Introducing a fluid (engine oil) into chambers ( 35 a ) through line ( 33 ) while draining fluid from chambers ( 35 b ) through line ( 34 ) rotates the rotor ( 31 ) counterclockwise relative to the housing ( 32 ), thus advancing (for example) the timing of the camshaft ( 30 ) relative to the crankshaft (not shown). Similarly, introducing the oil into chambers ( 35 b ) through line ( 34 ) while draining fluid from chambers ( 35 a ) through line ( 33 ) rotates the rotor ( 31 ) clockwise relative to the housing ( 32 ), thus retarding (for example) the timing of the camshaft ( 30 ) relative to the crankshaft (not shown).
The phaser in FIG. 3 is equipped with a lock mechanism, shown as a piston ( 37 ) in the housing ( 32 ), which is normally pressed against the rotor ( 31 ) to lock it, but can be unlocked by introduction of oil under pressure into line ( 38 ). When the piston ( 37 ) presses against the rotor ( 31 ), the rotor ( 31 ) and housing ( 32 ) are constrained to rotate together, which will be termed “locked” in this description. When the oil pressure releases the piston ( 37 ), the rotor ( 31 ) and housing ( 32 ) are free to rotate relative to one another under the control of the fluid pressure in lines ( 33 ) and ( 34 ) (within the limits set by the size of the chambers, of course), and this is termed “unlocked”.
It will be understood that the method of the invention requires only that there be a cam phaser which has a locking system. No particular phaser design or locking system is required by the invention, and the piston arrangement and vane phaser shown in FIG. 3 is for the purposes of example and explanation only.
The forces on the timing drive can be affected by the cam phaser in a number of ways. The crankshaft-timing drive (chain)-phaser-camshaft system can be thought of as a spring system. The spring system has one inertia characteristic when the drive and camshaft are rigidly connected (i.e. phaser locked), and a lower inertia characteristic when they are connected hydraulically (i.e. phaser unlocked).
When the device is locked, it has a similar stiffness to a fixed timing drive, but with several times the inertia of a conventional cam drive (sprocket, pulley, or gear). In addition to the increase in inertia, the cam phaser adds a great deal of viscous damping and compliance to the system. These characteristics change when the cam phaser is unlocked.
It will be understood that while the examples below show effects of fully locking or fully unlocking the cam phaser, for the purposes of the method of the invention, the terms “locked” and “unlocked” include both binary systems in which the lock either rigidly clamps the rotor and housing together or leaves them completely free, or continuous systems in which the locking mechanism permits intermediate conditions which increase the friction between the rotor and housing without completely fastening them together. What is required by the method is a locking mechanism which changes the compliance condition—i.e. friction or locked status—between the timing drive and the camshaft (between the rotor and the housing, in the vane phaser system as shown in FIG. 3 ).
The method of the invention comprises using these changes in characteristics due to compliance conditions in the phaser to minimize the effects of resonance in timing drives by changing between locked and unlocked states (or some condition between) as engine RPM passes through resonant points. FIGS. 1 a and 1 b , and 2 a and b , illustrate some of these effects.
FIGS. 1 a and 1 b show graphs of timing chain tension (vertical axis) vs. engine RPM (horizontal axis) in the primary chain of a representative V6 equipped with a VCT system. FIG. 1 a shows how maximum ( 10 ) and minimum ( 11 ) tensions vary with the phaser locked as the engine speed increases between approximately 700 and 7500 RPM. As can be seen, resonances cause peaks in the maximum ( 10 ) and dips in the minimum ( 11 ) lines at approximately 2500 RPM ( 12 ) and 5700 RPM ( 13 ). This would result in vibration and noise, and possibly additional stress and wear on the timing drive, when the engine is run at these speeds. With the phaser unlocked (FIG. 1 b ), the 5700 RPM resonance disappears, and the 2500 RPM resonance shifts ( 15 ) to approximately 2800 RPM.
Using the method of the invention with the engine of this example, the phaser would be locked at low RPM, then unlocked as engine RPM approached 2500 RPM ( 12 ), then locked again when the engine reached 2800 RPM ( 15 ). As engine speed increases, the phaser would once again be unlocked above a selected RPM of approximately 4500 RPM, where the minimum ( 11 ) and maximum ( 10 ) tension curves begin to diverge.
FIGS. 2 a and 2 b show resonance effects in another, very different, example engine—a four-cylinder engine equipped with a VCT system. This engine shows effects which require the method of the invention to choose the opposite at high RPM of the V6. In this example, it can be seen that the minimum ( 23 ) and maximum ( 22 ) tension lines with the phaser unlocked (FIG. 2 b ) diverge widely as the engine RPM exceeds about 5000 RPM ( 24 ). With the phaser locked (FIG. 2 a ), however, the minimum ( 21 ) and maximum ( 20 ) torques remain much closer together as the RPM increases.
Thus, in the engine of FIGS. 2 a and 2 b , the phaser would be unlocked at lower RPM, then locked as the RPM passes a selected point above approximately 5000 RPM ( 24 ), where the resonance effects change.
Thus, it can be seen that the method of the invention is performed by:
1. Recording the timing drive forces over a range of engine RPM, both with the phaser locked and with the phaser unlocked.
2. Analyzing the recorded timing drive forces to identify resonance effects.
3. While the engine is operating, choosing the locked or unlocked status of the phaser at a given RPM to minimize effects of resonance identified in step 2.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
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A method of controlling resonances in timing drive systems for internal combustion engines having variable cam timing systems using cam phasers with the capability of being locked in position. Locking or unlocking the phaser changes the resonant characteristics of the timing drive system. The invention uses these changes in characteristics between locked and unlocked phasers to minimize the effects of resonance in timing drives by changing between locked and unlocked states as engine RPM passes through resonant points.
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REFERENCE CITED
1. U.S. Pat. No. 6,221,702.
2. U.S. Pat. No. 6,541,323.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of fabricating polysilicon film by Nickel (Ni) and Copper (Cu) induced lateral crystallization, particularly to process under low-temperature annealing condition being about 10 times faster than that induced by Ni alone while keeping the similar grain size. Therefore, this invention substantially reduces the processing time, thereby increasing the industrial applicability adopting the method.
2. Discussion of the Related Art
At present the hydrogenated armophous silicon (a-Si:H) thin film was applied to various areas, i.e., the solar battery in calculators; the thin film transistor (TFT) as a switching element in a active matrix liquid crystal display (AMLCD). AMLCDs have been used in notebook computer and digital camera and gradually replaced the conventional cathode ray tube (CRT) in monitors and desktop computers. However, the field effect mobility of a-Si:H is low, i.e., ˜0.5 cm 2 /V-sec, which limits its performance. A polysilicon TFT is able to provide higher field effect mobility, i.e., >50cm 2 /V-sec, and reduce the response time of display than that of an amorphous silicon TFT. Traditionally, there are three ways to grow low temperature polysilicon thin film.
(a) direct growth of polysilicon thin film by high-temperature heat treatment,
(b) conversion of an amorphous silicon (a-Si:H) thin film to polysilicon by Ni induced crystallization,
(c) conversion of an amorphous silicon (a-Si:H) thin film to polysilicon by excimer laser annealing.
In (a), a polysilicon thin film can be grown by low pressure chemical vapor deposition (LPCVD) at a temperature above 600° C. Since the glass substrate of LCD becomes soft at temperature higher than 600° C., an expensive quartz substrate must be used, thereby increasing the fabrication cost.
In (b), the amorphous silicon (a-Si:H) film was first deposited on glass substrate by plasma enhanced chemical vapor deposition (PECVD) or LPCVD. Ni is deposited either on or under the amorphous silicon (a-Si:H) film. Then that was annealed at a temperature below 600° C. to crystallize a-Si:H. When that was annealed at 550° C. for 20 h, the range of crystallization is about 30 μm from the edge of Ni bars and the growth rate of polysilicon is 1.5 μm per hour. If the annealing time is shorter, the growth rate increases to about 2 μm per hour, This method requires a long processing time, causes difficulties in mass production. The use of Cu improves the growth rate of polysilicon, i.e., approximately 4 to 10 times larger than that of Ni induced polysilicon, but the grain size is 10 times smaller, it is difficult to achieve high field effect mobility and reduce the response time of LCD.
In (c), the amorphous silicon (a-Si:H) film was first deposited on glass substrate by PECVD or LPCVD. then excimer laser was used to anneal the a-Si:H film to form polysilicon crystallization. Although the process time decreases but the grain size is smaller, the electrical characteristic of the TFT is worse than that of Ni induced polysilicon.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a method of fabricating polysilicon film that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
The main object of present invention is to provide a method of fabricating polysilicon film which improves the growth rate of polysilicon thin film by mean of applying low-temperature annealing to hydrogenated amorphous silicon (a-Si:H) thin film.
Another object of the present invention is to provide a fabrication method for a polysilicon film having reliable electrical characteristics.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the present invention includes the steps:
a) evaporating a 1-nm to 50-nm-thick Copper (Cu) on substrate;
b) evaporating a 1-nm to 50-nm-thick Nickel (Ni) on said Copper (Cu);
c) forming a 1-nm to 200-nm-thick amorphous silicon thin film on thereof obtained according to b) including the Copper (Cu) and Nickel (Ni): and
d) forming a polysilicon thin film on thereof obtained according to c) by below 600° C. annealing.
Also, the present invention includes a fabrication method for polysilicon film comprising the faster growth rate of polysilicon thin film under below 600° C. annealing condition, i.e., this invention substantially reduces the processing time, thereby increasing the industrial applicability adopting said method.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the following detailed description of preferred embodiments of the invention, taken in conjunction with the accompanying flow diagram, in which
FIG. 1 is a diagram showing Nickel and Copper (Ni/Cu) induced lateral crystallization of polysilicon thin film before thermal annealing according to the present invention;
FIG. 2 is a diagram showing Ni/Cu induced lateral crystallization of polysilicon thin film after thermal annealing according to the present invention;
FIG. 3 is a diagram showing the Raman spectrum of annealed polysilicon film;
FIG. 4 (A) is a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 2 h according to the present invention:
FIG. 4 (B) is a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 4 h according to the present invention;
FIG. 4 (C) is a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 6 h according to the present invention;
FIG. 5 (A) is a diagram showing the bright field image of transmission electron microscopy (TEM) of Ni/Cu induced lateral crystallization of polysilicon according to the present invention;
FIG. 5 (B) is a diagram showing the TEM dark field image of Ni/Cu induced lateral crystallization of polysilicon according to the present invention; and
FIG. 5 (C) is a diagram showing transmission electron diffraction (TED) pattern of Ni/Cu induced lateral crystallization of polysilicon according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following descriptions of the preferred embodiments are provided to understand the features and the structures of the present invention.
FIG. 1 illustrates a diagram showing Ni/Cu induced lateral crystallization of polysilicon thin film before thermal annealing. FIG. 2 illustrates a diagram showing Ni/Cu induced lateral crystallization of polysilicon thin film after thermal annealing. FIG. 3 illustrates the Raman spectrum of annealed polysilicon film. FIG. 4 (A) illustrates a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 2 h. FIG. 4 (B) illustrates a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 4 h. FIG. 4 (C) illustrates a diagram showing optical micrograph of Ni/Cu induced lateral crystallization of polysilicon thin film after annealing at 550° C. for 6 h. FIG. 5 (A) illustrates a diagram showing TEM bright field image of Ni/Cu induced lateral crystallization of polysilicon. FIG. 5 (B) illustrates a diagram showing TEM dark field image of Ni/Cu induced lateral crystallization of polysilicon. FIG. 5 (C) illustrates a diagram showing transmission electron diffraction of Ni/Cu induced lateral crystallization of polysilicon. From FIG. 1 to FIG. 5 the present invention provides a method of fabricating polysilicon thin film by Ni/Cu induced lateral crystallization which can be used to fabricate the thin film transistor (TFT) in liquid crystal display (LCD). Furthermore, because Cu, Ni and amorphous silicon form the silicide, the latent heat released together with the migration of nickel silicide crystallize amorphous silicon to polysilicon. Therefore, if the amorphous silicon thin film 4 is deposited on top of Cu 2 and Ni 3 , the polysilicon 5 can be formed by annealing at a temperature below 600° C. In addition, the process time substantially reduces, thereby increasing the industrial applicability adopting said method that is proposed to the following step:
a) evaporate a 1-nm to 50-nm-thick Cu 2 on substrate. The substrate is selected from the group consisting of grass, insulating material and semiconductor. The Cu 2 is selected from the group consisting of Copper-Nickel alloy, and multiple-element alloy including Copper and Nickel.
b) Evaporate a 1-nm to 50-nm-thick Ni 3 on said Cu 2 . The Ni 3 is selected from the group consisting of Copper-Nickel alloy, and multiple-element alloy including Copper and Nickel. The method can change from a) and b) to b) and a) In order;
c) Form a 1-nm to 200-nm-thick amorphous silicon thin film 4 on thereof obtained according to b) including the Cu 2 and Ni 3 . It further comprising amorphous silicon thin film 4 being doped with Cu 2 and Ni 3 by ion-implantation and it further comprising to form amorphous silicon thin film 4 by chemical vapor deposition (CVD). CVD is plasma enhanced chemical vapor deposition (PECVD) or low pressure chemical vapor deposition (LPCVD).
d) Form a polysilicon thin film 5 on thereof obtained according to c) being processed under annealing temperature below 600° C.
Referring to FIG. 1, the Cu 2 and Ni 3 evaporated on the substrate. Then, the amorphous silicon thin film 4 is formed by a evaporation or deposition. After the amorphous silicon thin film 4 is formed thereon, that was prepared with processes under annealing below 600° C. for forming a polysilicon thin film 5 . The annealing temperature high enough for fast growth rate of polysilicon thin film 5 is reached. After the annealing is finished, a polysilicon thin film 5 implements a fabricating polysilicon film in the FIG. 2 .
FIG. 3 shows the diagram of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 adopting the Raman spectrum according to the present invention in which the thickness of amorphous silicon thin film 4 is 65 nm, the thickness of Cu 2 is 4 nm, the thickness of Ni 3 above Cu 2 is 4 nm, the annealing temperating is 550° C., and annealing time is 10 h. It is clear from the FIG. 3 that the Raman specturm display peak position at 519.16 cm −1 . In other words, the Cu 2 and Ni 3 can induce polysilicon thin film 5 having high quality crystallinity in said method.
FIG. 4 shows the optical microscope picture of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 in which the thickness of amorphous silicon thin film 4 is 65 nm, the thickness of Cu 2 is 4 nm, the thickness of Ni 3 is 4 nm. Because the refractive indexes of amorphous silicon and polysilicon are different, they can be distinguished under the optical microscope. The growth rate of polysilicon thin film 5 is easily calculated from the picture. FIG. 4 (A) is a diagram showing optical micrograph of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 after annealing at 550° C. for 2 h according to the present invention in which the growth rate of polysilicon thin film 5 is about 22 μm per hour. FIG. 4 (B) is a diagram showing optical micrograph of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 after annealing at 550° C. for 4 h according to the present invention in which the growth rate of polysilicon thin film 5 is about 25 μm per hour. FIG. 4 (C) is a diagram showing optical micrograph of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 after annealing at 550° C for 6 h according to the present invention in which the growth rate of polysilicon thin film 5 is about 25 μm to 30 μm per hour.
FIG. 5 shows the TEM image of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 in which the thickness of amorphous silicon thin film 4 is 65 nm, the thickness of Cu 2 is 4 nm, the thickness of Ni 3 is 4 nm, the annealing temperating is 550° C. and annealing time is 10 h. FIG. 5 (A) is a diagram showing TEM bright field image. FIG. 5 (B) is a diagram showing TEM dark field image. FIG. 5 (C) is a diagram showing transmission electron diffraction (TED) pattern of polysilicon thin film 5 . Referring to FIG. 5 (A) and FIG. 5 (C), the average grain size of Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 is about 0.35 μm.
The characteristics of present invention are proposed as follow:
(1). the method is used to crystallize a large-area amorphous silicon to polysilicon thin film 5 without scanning.
(2). The substrate for Cu 2 and Ni 3 induced lateral crystallization of polysilicon thin film 5 is selected from the group consisting of glass, insulating material and semiconductor.
(3). The area of polysilicon thin film 5 close to the Cu 2 and Ni 3 bars is suitable for a wide scope of applications.
To sum up the above mentioned, the present invention is inventive, innovative and progressive. The patent for this present invention is hereby applied for. It should include all variations and versions covered by the present invention, including possible minor improvements and more exact definitions.
The above mentioned practical examples are used to describe the invention in more detail, they should therefore be included in the range of the invention, but should not restrict the invention in any way.
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The present invention relates to a method of fabricating polysilicon film by Nickel and Copper induced lateral crystallization for the TFT-LCD, comprising the step of: a) a thin (˜4 nm) Copper and Nickel being evaporated onto the substrate; b) a amorphous-silicon film (˜50 nm) being evaporated onto thereof obtained according to a); c) applying annealing at less than 600° C. to thereof obtained according to b) for fast fabricating poly-silicon film. It is approximately 10 times faster than that of Ni induced polysilicon. The present invention is to provide a low-temperature (<600° C.) fast growth rate process to convert the hydrogenated amorphous silicon (a-Si:H) films to polysilicon film for substantially time-saving process and industrial applicability.
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The present invention relates to luminescence indicators for determining ionized calcium in a sample as well as optical sensors comprising these luminescence indicators. The invention also relates to a method of determining calcium ions in a sample using the luminescence indicators of the invention.
BACKGROUND OF THE INVENTION
For determining the calcium ions, the sample is contacted at least indirectly with a luminescence indicator (=luminophore-ionophore) having a luminophoric moiety and an ionophoric moiety, which ionophoric moiety reacts with the calcium ions present in the sample, whereupon the luminescence of the luminophoric moiety is measured and the concentration or the activity of the ionized calcium is deduced utilizing the test reading, i.e. the calcium ion is determined.
A determination method of this type is based on the reversible binding of calcium ions to a Ca 2+ -selective ionophore and on the so-called “PET effect” between the ionophore and a luminophoric moiety.
The reversible binding of calcium ions to the ionophore proceeds according to the principle of mass action (Equation 1): ICa 2 + Kd I + Ca 2 + ( 1 )
wherein, at a given ionic strength and temperature, the dissociation constant (K d ) is given by Equation 2, K d = c I c Ca 2 + c I _ Ca 2 + ( 2 )
wherein I means the ionophore with the charge number −2, ICa the ionophore-ion complex and c the concentration. In the following, K d and cCa 2+ are given in mol/l and mmol/l, respectively.
The PK d value (Equation 3) is the negative common logarithm of the dissociation constant:
PK d =−log(K d ) (3)
The term “PET effect” denotes the transfer, induced by photons, of electrons (photoinduced electron transfer=PET) from the ionophoric moiety or ionophore to the luminophoric moiety or luminophore, which causes a decrease in the (relative) luminescence intensity and the luminescence decay time of the luminophore. Absorption and emission wavelengths of the luminophoric moiety or luminophore, respectively, remain basically unaffected in the process (J. R. Lakowicz in “Topics in Fluorescence Spectroscopy”, Volume 4: Probe Design and Chemical Sensing; Plenum Press, New York & London (1994)).
By the binding of ions to the ionophore, the PET effect is reduced or completely suppressed, so that there is an increase in the luminescence of the luminophoric moiety. Hence, the concentration or the activity of the ion to be determined can be deduced by measuring the change in luminescence properties, i.e. luminescence intensity and/or luminescence decay time.
In mammals, calcium plays important physiological roles. These roles include: (1) controlling blood coagulation by activating the formation of thrombin from prothrombin, (2) excitation of muscle, heart and nerve cells, including acting as a second messenger like cAMP.
Measurement of extracellular ionized calcium is an essential part of medical diagnostics. The measurement of ionized calcium, blood gases and potassium is mandatory to allow for the maintenance of good cardiac function during liver transplant operations or other operations that require bypassing the heart and lung functions and using artificial life support.
Ion selective electrodes (ISE) have been used for determining calcium ions in body fluids for many years. Serious drawbacks of electrochemical measuring arrangements are the requirement of a reference element, sensitivity towards electrical potentials and electromagnetic interference. While ion-selective electrodes are rugged and reliable, they are expensive to use in a disposable device application. In addition, these electrodes require an electrical connection of the sample measurement device to the instrument.
However, optical methods or optical sensors do not require a reference element. The optical signals are independent of external potentials and currents. Such optical methods of determining calcium as are known to date are based f.i on the measurement of the luminescence intensity or luminescence decay time of a calcium-specific luminescence indicator or the light absorption of a calcium-specific absorption indicator, which depend directly or indirectly on the concentration or activity of calcium ions.
In order to determine intracellular calcium concentrations, indicators which change their absorption and/or luminescence properties by reversible binding of calcium ions (see above, Equation 1) are, e.g., used. Suitable indicators for intracellular calcium determination are based e.g. on tetracarboxylate Ca 2+ chelating compounds having the octacoordinate ligating group characteristics of EGTA (=ethylene glycol bis(-beta-aminoethyl ether)-N,N,N′,N′-tetraacetic acid) and BAPTA (=1,2-bis(2-aminophenoxy)ethane N,N,N′,N′-tetraacetic acid).
U.S. Pat. No. 4,603,209 e.g. discloses the BAPTA analogs which are electronically coupled to one or two fluorescent dye molecules capable of being excited in the UV range. By the binding of calcium ions to the ionophore, the absorption wavelength of the dye (a stilbene derivative) is changed. By means of suitable electron-withdrawing or electron-donating substituents it is feasible to change the calcium dissociation constant in the range of 80 to 250 nmol/l.
U.S. Pat. No. 5,049,673 further describes BAPTA analogs which—in electronically decoupled condition—are bound to xanthene dyes (fluoresceines, rhodamines). As a result of the electronic decoupling from the fluorophore, a PET effect occurs which is recognizable from the constant spectral position of the fluorescence emission band and the increasing fluorescence intensity depending on increasing concentrations of Ca 2+ (see FIG. 4 a of the reference). From the low K d values it can be seen that the fluoroionophores described (see FIG. 6 of the reference) are not useful for the determination of millimolar concentrations of Ca 2+ in whole blood or blood plasma.
As a consequence of the very low dissociation constant, such calcium-ionophores are useful for determining Ca 2+ in samples having correspondingly low calcium values, such as e.g. intracellular Ca 2+ . In contrast to this, blood plasma for example has Ca 2+ concentrations in the range of about 0.4-2 mmol/l. Suitable ionophores for optical determination of Ca 2+ in the blood or blood plasma thus must have correspondingly high K d values. Ideal K d values lie within the expected range of the Ca 2+ concentrations or activities to be determined.
From U.S. Pat. No. 5,516,911, fluorescent indicators based on fluorinated BAPTA derivatives are known which have K d values in the millimolar range. One major disadvantage with this method is the very complicated synthesis of fluorinated BAPTA derivatives.
Moreover, the known ionophores based on BAPTA or on derivatives thereof in an aqueous environment and at normal ambient temperatures are not particularly stable chemically (see U.S. Pat. No. 4,603,209, column 26, lines 40-46). This is particularly disadvantageous in determination procedures using optical sensors in measuring situations requiring a high shelf life (durability) of the sensor or where, for monitoring purposes, one sensor is to be used for measuring over prolonged time periods.
The present invention aims at avoiding these disadvantages and problems and has as its object to provide luminophore-ionophores for the optical determination of calcium ions, whose ionophores if compared to such BAPTA compounds as are known to date, in particular fluorinated derivatives, are more easily synthesizable and—in electronically decoupled condition—can be covalently bound to suitable luminophores.
Further, the ionophores of the provided luminophore-ionophores are to exhibit K d values allowing the determination of physiological calcium values without requiring previous diluting of the sample material, wherein, by means of suitable substituents, the K d values are to be adjustable with regard to the expected values of the concentrations of Ca 2+ in the sample material which are to be determined.
In addition, it is to be possible for the luminophore-ionophores to be bound to a hydrophilic polymer material by means of a chemical group in order to use them in optical sensors.
Preferred luminophore-ionophores should not exhibit inherent pH dependence in the expected pH range of the sample and should be excitable by light of commercially available LEDs (preferably >420 nm). These luminophore-ionophores should, in addition, be chemically stable in an aqueous environment even at high ambient temperatures and over prolonged time periods (>3 months).
SUMMARY OF THE INVENTION
The present object is achieved in that a compound having the general Formula I:
including its salts is provided, where Z is either the group having the general Formula II:
where
R 1 is alkyl having 1-4 C atoms, alkoxyalkyl having 2-5 C atoms or aryloxyalkyl whose alkyl group has 1-4 C atoms,
R 2 is alkyl having 1-4 C atoms or alkoxyalkyl having 2-5 C atoms,
R 3 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 ,
Y is H 2 or O and
L is a luminophoric moiety in a position para or meta to the nitrogen,
or is the group having the general Formula III:
where
n is 2or 3,
R 4 is alkyl having 1-4 C atoms or alkoxyalkyl having 2-5 C atoms,
R 5 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 and
L is a luminophoric moiety in a position para or meta to the nitrogen,
or is the group having the general Formula IV:
where
R 6 is alkyl having 1-3 C atoms or phenyl,
R 7 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 and
L is a luminophoric moiety in a position para or meta to the nitrogen.
Thus, the compounds of the invention have the following general formulae:
where R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , Y, L and n have the meaning indicated above. The ionophores of the compounds of the invention are based on the basic structure of the o-anisidine with a diacetate group and can be synthesized in a simple manner (see below).
The K d values of the ionophores of the invention lie within a range that makes them useful in particular for the determination of physiological concentrations of Ca 2+ (see examples shown in Table 1: K d =0.2-123 mmol/l Ca 2+ ). The K d values can be adjusted by means of suitable substituents (see below).
Due to the aliphatically bound nitrogen of the imino-N,N-diacetate ligand portion the ionophores of the invention having a group of the general Formula II exhibit an inherent pH-dependence at a neutral pH and are not stable in an aqueous environment over a prolonged time period. Basically, however, these ionophores are applicable for any measuring situation in which the pH of the sample is known or can be adjusted to a known value by means of a pH buffer and if there is no need for a prolonged useful life in an aqueous environment.
In the compounds of the invention having a group of the general Formula II, R 1 is preferably alkyl having 4 C atoms, alkoxyalkyl having 3-4 C atoms or aryloxyalkyl whose alkyl group has 2 C atoms. R 2 is preferably alkyl having 1-4 C atoms, more preferably methyl. R 3 is advantageously located in a position para to the oxygen of the o-anisidine and is preferably H or methoxy.
The particularly advantageous ionophores of the compounds having a group of the general Formula III do not exhibit an inherent pH-dependence at physiological pH values (presumably even alkaline ones) and in an aqueous environment at normal ambient temperature are chemically stable even over prolonged time periods. These ionophores are likewise based on the structure of the o-anisidine and a diacetate. However, in contrast to the ionophores of the group having the general Formula II they do not comprise aliphatically bound nitrogen. The two carboxyl ligand portions are bound to the aromatic nitrogen of the o-anisidine in the form of diethoxyacetate groups.
In the compounds of the invention having a group of the general Formula III it is preferred that n=2. R 4 preferably is alkyl having 1-2 C atoms. R 5 is advantageously located in a position para to the oxygen of the o-anisidine and is preferably H or ethoxy or Cl.
The ionophores of the compounds having a group of the general Formula IV exhibit similar advantages if compared to ionophores having a group of the general Formula III.
In the compounds of the invention having a group of the general Formula IV, R 6 preferably is methyl. R 7 advantageously is located in a position para to the oxygen of the o-anisidine and is preferably H.
Suitable luminophoric moieties L can be chemically bound to the ionophores of the invention via a —(CH 2 ) n — spacer, wherein n preferably means the numbers 1 and 2 but can also be 0. Suitable luminophoric moieties are basically all luminophoric moieties which, in combination with the ionophores of the invention, afford a PET effect (see above).
Those skilled in the art will be aware that in order for a PET effect to materialize it is essential in particular that the electron donor of the ionophoric moiety be electronically decoupled from the electronic system of the luminophoric moiety. As is well known in the art, such electronic decoupling of the ionophoric and luminophoric moieties may be achieved in that the two moieties present are separated either by a spacer group, that is e.g. a (CH 2 ) n chain or—if n=0—by a virtual spacer (e.g. by pivoting the plane of the luminophoric moiety to the plane of the benzene ring). Hence, the function of the spacer is to oppose conjugation of the electron system of the ionophoric moiety with the electron system of the luminophoric moiety.
Electronic decoupling can be recognized e.g. from the fact that the wavelengths of the absorption and emission spectra of the luminophoric moiety do not change significantly with the calcium concentration.
Preferred luminophoric moieties are those that are capable of being excited by light of commercially available LEDs, that do not exhibit an inherent sensitivity towards pH (and O 2 ) and that in the form of the luminophore-ionophore compound exhibit stability in an aqueous environment over a prolonged time period. Further it is to be feasible for chemical groups to be added at the luminophoric or the ionophoric moiety, but preferably at the luminophore, by means of which chemical groups the luminophore-ionophore can be bound to a hydrophilic polymer matrix, preferably covalently.
Examples of suitable luminophoric moieties are luminescent derivatives of naphthalimide, of the difluorobora-3a,4a-s-indacenes and of xanthenones (e.g. fluoresceines and rhodamines).
In the compounds of the invention, the luminophoric moiety L is preferably located in a position para to the nitrogen.
The compounds of the invention of the general Formula I can be present as free dicarboxylic acids or in the form of the salts thereof. Advantageously, the compounds are present in the form of the dipotassium salt.
The invention also relates to an optical sensor for determining calcium ions in a sample, which sensor has a matrix comprising a compound having a luminophoric moiety and an ionophoric moiety, wherein the compound being used is a compound having a group of the general Formula I.
The invention further provides a method of determining calcium ions in a sample, wherein the calcium ions are brought into at least indirect contact with a compound having a luminophoric moiety and an ionophoric moiety, which ionophoric moiety reacts with the calcium ions present in the sample, wherein the luminophoric moiety changes its luminescence properties, whereupon the luminescence is measured and the calcium ions are determined using the test readings, wherein the compound being used is a compound having a group of the general Formula I.
In addition, the invention relates to the use of a compound having a group of the general Formula I in an optical sensor for the determination of calcium ions in a sample.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of calcium ionophores in accordance with invention;
FIGS. 2A, 2 B and 2 C are illustrations of synthetic schemes for preparing calcium ionophores X1 and X9 shown in FIG. 1, X2, X3, X4 and X4 shown in FIG. 1, and X6, X7 and X8 shown in FIG. 1, respectively;
FIGS. 3A and 3B are illustration of synthetic schemes for preparing a luminophore-ionophore according to the invention starting from 2, 5-dimetlioxyphenethylamine and 2, 5-dihydroxybenzaldehyde, respectively;
FIG. 4 is a graph of relative absorption values versus C a 2+ concentration for ionophores in accordance with the invention;
FIG. 5 is a schematic illustration of a measuring arrangement including sensor discs prepared in accordance with the invention;
FIG. 6 is a graph of relative luminescence intensity versus negative common logarithm of calcium concentration for three luminophore-ionophore immobilized on amiriocellulose in accordance with the invention; and
FIG. 7 is a graph of relative luminescence intensity versus pH for two luminophore-ionophores according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, the invention will be described more fully by means of examples, wherein the synthesis and the properties of some compounds that are preferably used will be explained. Other compounds of the invention can be prepared in analogous manner by those skilled in the art.
1. Synthesis of ionophores of the invention
FIG. 1 shows the formulae of the calcium ionophores (X1-X9) of the invention synthesized in the following examples.
Synthesis of the calcium ionophores of the invention can be divided into three general synthetic strategies.
The first synthetic strategy is based on monoalkylation of o-anisidine which subsequently is alkylated with diethyl N-(2-bromoethyl)iminodiacetate (M9). Compounds X2, X3, X4 and X5 belong to this category. The synthetic scheme for these compounds is shown in FIG. 2 B.
The second synthetic strategy is based on dialkylation of o-alkoxy anilines. The alkylation agent for compounds X6, X7 and X8 was ethyl 2-chloroethoxyacetate (M25). The synthetic scheme for these compounds is shown in FIG. 2 C.
The third synthetic strategy including compounds X1 and X9 did not use the same intermediate. These compounds were prepared according to individual synthetic schemes shown in FIG. 2 A.
1.1. Synthesis of potassium N-[2-(N′,N′-dimethoxyethyl)aminophenoxyethyl]imino-N,N-diacetate (X9, see FIG. 2A)
1.1.1 2-(2-Bromoethoxy)-nitrobenzene (M2)
A suspension of 35.4 g (200 mmol) potassium 2-nitrophenolate, 112.7 g (600 mmol) 1,2-dibromoethane in 100 ml DMF was heated at 120° C. for 3 hours. The mixture was cooled and diluted with 400 ml CHCl 3 , washed with 3×400 ml 2.5% Na 2 CO 3 till the aqueous layer became almost colorless, was then washed with 400 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated and the residue was triturated with 50 ml methanol, the resultant precipitate was filtered off (dimer). The filtrate was concentrated to afford 22.7 g oil, which solidified after cooling to room temperature. Upon recrystallizing from methanol/water (95/5, v/v), 17.8 g off-white crystals were obtained (yield: 36.2%).
1 H-NMR (CDCl 3 ), δ (ppm): 3.68 (t, 2H), 4.42 (t, 2H), 7.08 (m, 2H), 7.55 (m, 1H), 7.83 (m, 1H).
1.1.2 Diethyl-N-(2-nitrophenoxyethyl)imino-N,N-diacetate (M3)
A mixture of 2.46 g (10 mmol) M2, 2.08 g (11 mmol) diethyl iminodiacetate M8 (see FIG. 2 B), 1.52 g (11 mmol) K 2 CO 3 , 0.83 g (5 mmol) KI and 10 ml DMF was heated at 85° C. for 20 hours, cooled and diluted with 50 ml CHCl 3 and 50 ml water. The organic phase was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 4.10 g crude oil. This oil was purified by a silica gel column with CHCl 3 and cyclohexane as eluant, wherein 2.68 g clear oil were obtained (yield: 76%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 3.25 (t, 2H), 3.69 (s, 4H), 4.14 (m, 4H), 4.27 (t, 2H), 6.98-7.10 (m, 2H), 7.51 (m, 1H), 7.84 (m, 1H).
1.1.3. Diethyl N-(2-aminophenoxyethyl)imino-N,N-diacetate (M4)
2.60 g (7.3 mmol) of M3 and 0.26 g 10% Pd/C was suspended in 50 ml absolute ethanol, hydrogenated at 30 psi for 2 hours and filtered. The solvent was evaporated to afford 2.20 g light yellow oil (yield: 92%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 3.20 (t, 2H), 3.65 (s, 6H, inc. NH 2 ), 4.18 (m, 6H), 4.27 (t, 2H), 6.70-6.80 (m, 4H, Ar.).
1.1.4. Diethyl-N-[2-(N′,N′-dimethoxyethyl)aminophenoxyethyl]imino-N,N-diacetate (M5)
A suspension of 1.62 g (5 mmol) M4, 23.5 g (350 mmol) chloroethyl methyl ether, 1.65 g (12 mmol) K 2 CO 3 , 1.0 g (6 mmol) KI in 25 ml DMF was heated at 95° C. for 18 hours. Most of DMF and unreacted chloroethyl methyl ether were evaporated. The residue was dissolved in 100 ml CHCl 3 and 100 ml saturated NaCl. The organic phase was dried over Na 2 SO 4 . The solvent was evaporated to give 2.21 g oil. This crude oil was purified with silica gel 100 using CHCl 3 as eluant to afford 0.64 g pure product (yield: 29%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.23 (t, 6H), 3.20 (t, 2H), 3.32 (t, 2H), 3.40 (t, 4H), 3.60 (t, 2H), 3.65 (s, 4H), 4.18 (m, 6H), 6.60-6.85 (m, 4H, Ar.).
1.1.5. Potassium N-[2-(N′,N′-dimethoxyethyl)aminophenoxyethyl]imino-N,N-diacetate (X9)
0.25 ml water and 0.09 g (1.5 mmol) KOH were added to a solution of 0.22 g (0.5 mmol) M5 in 4.75 ml methanol. The resultant solution was heated to 60° C. for 5 min and then stirred at room temperature for 4 hours. Thin-layer chromatography showed that all ester was hydrolyzed. The concentration of X9 in this final solution was 100 mmol/l. 5 ml of this solution was diluted to 1000 ml with HEPES buffer (pH 7.3) containing 140 mmol/l Na + , 5 mmol/l K + and 110 mmol/l Cl − . The UV-absorption curves presented in FIG. 4 were measured with this solution spiked with different levels of CaCl 2 .
1.2. Synthesis of potassium N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aminoacetyl)]-imino-N,N-diacetate (X1, see FIG. 2A)
1.2.1. Diethyl-N-(bromoacetyl)imino-N,N-diacetate (M6)
A solution of 9.44 g (60 mmol) bromoacetyl chloride in 25 ml CH 2 Cl 2 was added to a solution of 9.5 g (50 mmol) diethyl iminodiacetate M8 (see FIG. 2B) and 6.07 g (60 mmol) triethylamine in 25 ml CH 2 Cl 2 at 0° C. The resultant suspension was stirred at room temperature for 4 hours, diluted with 150 ml CHCl 3 and washed with 200 ml water, 3×200 ml 0.1 N HCl, 3×200 ml saturated NaHCO 3 and 200 ml saturated NaCl and dried over Na 2 SO 3 . The solvent was evaporated to give 12.6 g oil. This oil was purified with a silica gel column using CHCl 3 /cyclohexane (1/1, v/v) as eluant to afford 9.25 g pure product (yield: 60%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 2.10 (s, 2H), 4.20 (m, 8H).
1.2.2. Diethyl N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aminoacetyl)]-imino-N,N-diacetate (M7)
A suspension of 0.73 g (4 mmol) M12 (for synthesis see 1.3.2. and FIG. 2 B), 1.86 g (6 mmol) M6 and 0.83 g (6 mmol) K 2 CO 3 in 6 ml acetonitrile was heated at 85° C. for 18 hour The mixture was cooled and diluted with 30 ml CHCl 3 and 30 ml water. The organic layer was washed with 30 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 2.55 g crude product. This oil was purified with a column packed with 13 g silica gel and eluted with CHCl 3 to collect pure product, wherein 0.96 g were obtained (yield 59%).
1 H-NNIR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 3.40 (t, 2H), 3.50 (t, 2H), 3.80 (s, 3H), 4.05 (s, 3H), 4.08 (s, 4H), 4.12 (q, 4H), 4.50 (s, 2H), 6.80-7.10 (m, 4H, Ar.).
1.2.3. Potassium N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aminoacetyl)]-imino-N,N-diacetate (X1)
As procedure similar to that described in Section 1.1.5. above was used to hydrolyze M7 and to obtain a solution of X1, which was used for absorption measurements.
1.3. Synthesis of potassium N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X2, see FIG. 2B)
1.3.1. Diethyl N-(2-bromoethyl)imino-N,N-diacetate (M9)
A solution of 9.5 g (50 mmol) diethyl iminodiacetate M8, 94.0 g (500 mmol) 1,2-dibromoethane and 7.8 g (60 mmol) diisopropylethylamine was heated at 85° C. for 18 hours. Subsequently it was cooled and diluted with 100 ml CHCl 3 and 100 ml water. The organic phase was washed with 2×200 ml water and 200 ml saturated NaCl and dried over Na 2 SO 4 . Solvent and unreacted dibromoethane were evaporated, the residue was purified with a silica gel column using CHCl 3 /cyclohexane (1/1, v/v) as eluant. 4.0 g clear oil was obtained (yield: 27%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.23 (t, 6H), 3.15 (t, 2H), 3.40 (t, 2H), 3.60 (s, 4H), 4.08 (m, 4H).
1.3.2. N-methoxyethyl-2-anisidine (M12)
A suspension of 24.6 g (200 mmol) o-anisidine M10, 20.8 g (220 mmol) chloroethyl methyl ether M11, 30.4 g (220 mmol) K 2 CO 3 and 18.3 g (110 mmol) KI in 110 ml DMF was heated at 95° C. for 24 hours. DMF was evaporated, and the residue was digested with 100 ml CHCl 3 , filtered, and the precipitate washed with 2×50 ml CHCl 3 . The solvent was evaporated to give 41.2 g crude oil. This oil was purified by a plug packed with 184 g silica gel 100 with CHCl 3 /cyclohexane (1:1, v/v) as eluant, to afford 23.5 g pure product (yield: 65%).
1 H-NMR (CDCl 3 ), δ (ppm): 3.28 (t, 2H), 3.40 (s, 3H), 3.65 (t, 2H), 3.78 (s, 3H), 6.35 (d, 1H), 6.60 (t, 1H), 6.78 (m, 2H).
1.3.3. Diethyl N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aninoethyl)]-imino-N,N-diacetate (M13)
A suspension of 0.36 g (2 mmol) M12, 0.65 g (2.2 mmol) M9 and 0.30 g (2.2 mmol) K 2 CO 3 in 2 ml DMF was heated at 85° C. for 18 hours. The mixture was cooled and diluted with 20 ml CHCl 3 and 20 ml water. The organic layer was washed with 20 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 1.05 g crude product. This oil was purified with a column packed with 5 g silica gel, wherein elution was carried out with CHCl 3 to remove unreacted M12 and with CHCl 3 /ethyl acetate (4/1, v/v) to collect the pure product. 0.33 g pure product were obtained (yield: 51%). 1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 2.85 (t, 2H), 3.30 (s, 3H), 3.35 (m, 4H), 3.40 (t, 2H), 3.60 (s, 4H), 3.80 (s, 3H), 4.18 (q, 4H), 6.80-7.05 (m, 4H, Ar.).
1.3.4. Potassium N-[2-(N′-methoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X2)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M13 and to obtain a solution of X2, which was used for absorption measurements.
1.4. Synthesis of potassium N-[2-(N′-ethoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X3, see FIG. 2B)
1.4.1. N-ethoxyethyl-2-anisidine (M15)
A suspension of 12.3 g (100 mmol) o-anisidine M10, 11.9 g (110 mmol) chloroethyl ethyl ether M14, 15.2 g (110 mmol) K 2 CO 3 and 9.1 g (55 mmol) KI in 55 ml DMF was heated at 95° C. for 18 hours. DMF was evaporated and the residue was dissolved in 100 ml CHCl 3 and 100 ml saturated NaCl. The organic layer was dried over Na 2 SO 4 . The solvent was evaporated to give 19.4 g crude oil. The crude oil was purified with a plug packed with 84 g silica gel 100 with CHCl 3 /cyclohexane (1:1, v/v) as eluant to afford 7.85 g pure product (yield: 40%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 3H), 3.30 (t, 2H), 3.58 (q, 2H), 3.65 (t, 2H), 3.78 (s, 3H), 6.35 (d, 1H), 6.60 (t, 1H), 6.78 (m, 2H).
1.4.2. Diethyl-N-[2-(N′-ethoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (M16)
A suspension of 0.59 g (3 mmol) M15, 1.33 g (4.5 mmol) M9 (for synthesis see 1.3.1.) and 0.62 g (4.5 mmol) K 2 CO 3 in 3 ml DMF was heated at 85° C. for 18 hours. The mixture was cooled and diluted with 50 ml CHCl 3 and 20 ml water. The organic layer was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 1.25 g crude product. This oil was purified with a column packed with 6 g silica gel, wherein elution was carried out with CHCl 3 to remove unreacted M15 and with CHCl 3 /ethyl acetate (4/1, v/v) to collect the pure product. 0.25 g pure product were obtained (yield: 26%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (m, 8H), 2.85 (t, 2H), 3.30 (q, 2H), 3.35 (m, 4H), 3.40 (t, 2H), 3.60 (s, 4H), 3.80 (s, 3H), 4.18 (q, 4H), 6.80-7.05 (m, 4H, Ar.).
1.4.3. Potassium N-[2-(N′-ethoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X3)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M16 and obtain a solution of X3, which was used for absorption measurements.
1.5. Synthesis of potassium N-[2-(N′-butyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X4, see FIG. 2B)
1.5.1. N-butyl-2-anisidine (M18)
A suspension of 6.2 g (50 mmol) o-anisidine M10, 7.5 g (55 mmiol) 1-bromobutane M17, 7.6 g (55 mmol) K 2 CO 3 and 0.91 g (5.5 mmol) KI in 25 ml DMF was heated at 95° C. for 24 hours. DMF was evaporated and the residue was dissolved in 100 ml CHCl 3 and 100 ml saturated NaCl. The organic layer was dried over Na 2 SO 4 . The solvent was evaporated to give 9.4 g crude oil. This oil was purified by a plug packed with 45 g silica gel 100 using cyclohexane as eluant, wherein 4.8 g pure product were obtained (yield: 55%).
1 H-NMR (CDCl 3 ), δ (ppm): 0.95 (t, 3H), 1.42 (m, 2H), 1.62 (m, 2H), 3.05 (m, 2H), 3.85 (s, 3H), 6.60-7.00 (m, 4H).
1.5.2. Diethyl-N-[2-(N′-butyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (M19)
A suspension of 0.36 g (2 mmol) M18, 0.65 g (2.2 mmol) M9 (for synthesis see 1.3.1.) and 0.30 g (2.2 mmol) K 2 CO 3 in 2 ml DMF was heated at 85° C. for 18 hours. The mixture was cooled and diluted with 25 ml CHCl 3 and 25 ml water. The organic layer was washed with 25 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 1.05 g crude product. This crude product was purified with a column packed with 5.5 g silica gel, wherein elution was carried out with CHCl 3 to remove unreacted M18 and with CHCl 3 /ethyl acetate (4/1, v/v) to collect the pure product. 0.31 g pure product were obtained (yield: 39%).
1 H-NMR (CDCl 3 ), δ (ppm): 0.92 (t, 3H), 1.20 (t, 6H), 1.25 (m, 2H), 1.40 (m, 2H), 2.80 (t, 2H), 3.05 (t, 2H), 3.20 (t, 2H), 3.55 (s, 4H), 3.80 (s, 3H), 4.18 (q, 4H), 6.80-7.05 (m, 4H, Ar.).
1.5.3. Potassium N-[2-(N′-butyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X4)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M19 and obtain a solution of X4, which was used for absorption measurements.
1.6. Synthesis of potassium N-[2-(N′-phenoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X5, see FIG. 2B)
1.6.1. N-(2-phenoxyethyl)-2-anisidine (M21)
A suspension of 6.2 g (50 mmol) o-anisidine M10, 12.1 g (60 mmol) β-bromophenetole M20 and 8.3 g (60 mmol) K 2 CO 3 in 25 ml acetonitrile was heated at reflux for 18 hours. The mixture was cooled, diluted with 100 ml CHCl 3 and washed with 100 ml water and 100 ml saturated NaCl. The organic layer was dried over Na 2 SO 4 . The solvent was evaporated to give 14.5 g crude oil. This oil was purified by a plug packed with 60 g silica gel 100 with cyclohexane as eluant, wherein 6.4 g pure product were obtained (yield: 51%).
1 H-NMR (CDCl 3 ), δ (ppm): 3.45 (t, 2H), 3.85 (s, 3H), 4.05 (t, 2H), 6.80-7.20 (m, 9H).
1.6.2. Diethyl N-[2-(N′-phenoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (M22)
A suspension of 0.97 g (4 mmol) M21, 1.78 g (6 mmol) M9 (for synthesis see 1.3.1.) and 0.83 g (6 mmol) K 2 CO 3 in 4 ml acetonitrile was heated at 85° C. for 18 hours. The mixture was cooled and diluted with 50 ml CHCl 3 and 50 ml water. The organic layer was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 2.60 g crude product. This oil was purified with a column packed with 13 g silica gel, wherein elution was carried out with CHCl 3 /cyclohexane (1/1, v/v) to remove unreacted M21 and with CHCl 3 /ethyl acetate (4/1, v/v) to collect the pure product. 1.20 g pure product were obtained (yield: 66%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 2.85 (t, 2H), 3.20 (t, 2H), 3.45 (t, 2H), 3.60 (s, 4H), 3.80 (s, 3H), 4.00 (t, 2H), 4.18 (q, 4H), 6.80-7.05 (m, 4H, Ar.).
1.6.3. Potassium N-[2-(N′-phenoxyethyl-N′-(2-methoxyphenyl)aminoethyl)]-imino-N,N-diacetate (X5)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M22 and obtain a solution of X5, which was used for absorption measurements.
1.7. Synthesis of potassium-o-anisidine-N,N-diethoxyacetate (X6, see FIG. 2C)
1.7.1. 2-Chloroethoxyacetic acid (M24)
100 g (800 mmol) 2-chloroethoxyethanol M23 was added slowly into 500 ml conc. HNO 3 (70%) at 55° C. within 8 hours. The solution was stirred at room temperature for 18 hours and heated in a boiling water bath for 1 hour, cooled and poured into 500 ml icy water. The diluted solution was extracted 8× with 11 CHCl 3 . All extracts were combined and evaporated to afford 54.2 g oil (yield: 49%). This oil was used directly for the next esterification without fuirther purification.
1.7.2. Ethyl-2-chloroethoxyacetate (M25)
54.1 g (390 mmol) M24 obtained from the preceding reaction step was dissolved in 380 ml absolute ethanol and 9 ml conc. H 2 SO 4 was added. The mixture was heated at reflux for 18 hours. Most of the ethanol was evaporated and the residue was dissolved in 400 ml CHCl 3 /100 ml water and basified with powder NaHCO 3 . The organic phase was washed with 2×400 ml saturated NaHCO 3 and dried over Na 2 SO 4 . The solvent was evaporated to afford 58.3 g clear oil (yield: 89%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 3H), 3.68 (t, 2H), 3.82 (t, 2H), 4.15 (s, 2H), 4.20 (q, 4H).
1.7.3. Diethyl-o-anisidine-N,N-diethoxyacetate (M26)
A suspension of 0.37 g (3 mmol) o-anisidine M10, 1.34 g (8 mmol) ethyl-2-chloroethoxyacetate M25, 1.10 g (8 mmol) K 2 CO 3 and 0.67 g (4 mmol) KI in 3 ml DMF was heated at 95° C. for 7 hours. Thin-layer chromatography showed that there was a lot of mono-alkylated product. 1.34 g (8 mmol) more ethyl-2-chlorethoxyacetate M25 and 1.10 g (8 mmol) more K 2 CO 3 were added. Heating was continued for another 18 hours. The mixture was cooled and diluted with 50 ml water/50 ml CHCl 3 . The organic phase was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 1.08 g crude oil. This oil was purified with a plug packed with 5 g silica gel 100 using cyclohexane/CHCl 3 as eluant to remove front impurities and then CHCl 3 /ethylacetate (4/1, v/v) were used, wherein 0.38 g light yellow oil were obtained (yield: 32%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.22 (t, 6H), 3.42 (t, 3H), 3.60 (t, 3H), 3.80 (s, 3H), 4.02 (s, 4H), 4.15 (q, 4H), 6.80-7.05 (m, 4H).
1.7.4. Potassium-o-anisidine-N,N-diethoxyacetate (X6)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M26 and obtain a solution of X6, which was used for absorption measurements.
1.8. Synthesis of potassium o-phenetidine-N,N-diethoxyacetate (X7, see FIG. 2C)
1.8.1. Diethyl o-phenetidine-N,N-diethoxyacetate (M28)
A suspension of 0.68 g (5 mmol) o-phenitidine M27, 2.50 g (15 mmol) ethyl 2-chloroethoxyacetate M25 (for synthesis see 1.7.), 2.07 g (15 mmol) K 2 CO 3 and 1.25 g (7.5 mmol) KI in 3 ml DMF was heated at 95° C. for 20 hours. The mixture was cooled and diluted with 80 ml water/80 ml CHCl 3 . The organic phase was washed with 80 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 2.05 g crude oil. This oil was purified with a plug packed with 5 g silica gel 100 using cyclohexane/CHCl 3 as eluant to remove front impurities and then using CHCl 3 /ethyl acetate (4/1, v/v). 0.84 g light yellow oil were obtained (yield: 42%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.22 (t, 6H), 1.42 (t, 3H), 3.42 (t, 3H), 3.62 (t, 3H), 4.02 (q, 2H), 4.05 (s, 4H), 4.20 (q, 4H), 6.80-7.05 (m, 4H).
1.8.2. Potassium o-phenetidine-N,N-diethoxyacetate (X7)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M28 and obtain a solution of X7, which was used for absorption measurements.
1.9. Synthesis of potassium 5-chloro-o-anisidine-N,N-diethoxyacetate (X8, see FIG. 2C)
1.9.1. Diethyl-5-chloro-o-anisidine-N,N-diethoxyacetate (M30)
A suspension of 0.78 g (5 mmol) 5-chloro-2-methoxy-aniline M29, 2.50 g (15 mmol) ethyl-2-chloroethoxyacetate M25 (for synthesis see 1.7.), 2.07 g (15 mmol) K 2 CO 3 and 1.25 g (7.5 mmol) KI in 30 ml DMF was heated at 95° C. for 18 hours. DMF was evaporated and the residue was diluted with 80 ml water/80 ml CHCl 3 . The organic phase was washed with 80 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 2.70 g crude oil. This oil was purified with a plug packed with 5 g silica gel 100 using cyclohexane/CHCl 3 as eluant to remove front impurities and then using CHCl 3 /ethylacetate (4/1, v/v). 0.54 g light yellow oil were obtained (yield: 26%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 6H), 3.45 (t, 3H), 3.62 (t, 3H), 3.80 (s, 3H), 4.02 (s, 4H), 4.20 (q, 4H), 6.60-7.05 (m, 3H).
1.9.2. Potassium 5-chloro-o-anisidine-N,N-diethoxyacetate (X8)
A procedure similar to that described in Section 1.1.5. above was used to hydrolyze M30 and obtain a solution of X8, which was used for absorption measurements.
2. Synthesis of luminophore-ionophores of this invention
Luminophore-ionophores based on naphthalimide were prepared by two different methods. The synthetic schemes are represented in FIGS. 3A and 3B.
A luminophore-ionophore using X3* as ionophore (corresponding to X3 in FIG. 1, except that in a position para to the oxygen of the o-anisidine H is replaced by methoxy) was synthesized starting from a commercially available precursor, 2,5-dimethoxyphenethylamine J1 (FIG. 3 A). This compound was nitrated in a HNO 3 /HCl mixture, followed by BOC-protection (BOC=t-butoxycarbonyl), hydrogenation, monoalkylation and deprotection, and was then coupled to the 4-chloronaphthalimide derivative C3, which contains a t-butyl protected carboxylic acid group. The resultant luminophore J7 was alkylated with M9 (see FIG. 2B) to give the triester J8. The t-butylester was removed by trifluoroacetic acid (TFA) and the free carboxy group was used for immobilization of J9 on aminocellulose. The ethyl ester was hydrolyzed in aqueous KOH to obtain the final product J11.
According to the same synthetic scheme there was also prepared a luminophore-ionophore using X2* (corresponding to X2 in FIG. 1, except that in a position para to the oxygen of the o-anisidine H is replaced by methoxy) as ionophore.
Another luminophore-ionophore using X7* as ionophore (corresponding to X7 in FIG. 1, except that in a position para to the oxygen of the o-anisidine H is replaced by ethoxy), was prepared from 2,5-dihydroxybenzaldehyde N2 as starting material (FIG. 3B) because the ethyl analog of J1 was not commercially available. N2 was alkylated with iodoethane and condensed with nitromethane to obtain the nitrostyrene derivative N4, which was reduced to the phenethylamine derivative N5. N5 was nitrated, hydrogenated and coupled to the 4-chloronaphthalimide derivative C3. The resultant amine N8 was alkylated with M25 (for synthesis see 1.7. and FIG. 2C) to obtain the triester N9, which was deprotected, immobilized on aminocellulose and hydrolyzed to obtain the final product N12.
2.1. Synthesis of a luminophore-ionophore using X3* as ionophore
2.1.1. 4-Nitro-2,5-dimethoxyphenethylamine (J2)
45.5 g (250 mmol) 2,5-dimethoxyphenethylamine J1 was mixed with 40 ml water and cooled to 0° C. while 30 ml conc. HCl was added slowly. The resultant milky emulsion was cooled to 0 to 5° C., and 65 ml conc. HNO 3 was added slowly and carefully within about 2 hours, keeping the temperature below 10° C. The mixture solidified when about half of the HNO 3 had been added. 50 ml icy water was added to render the mixture stirrable. Then the rest of the HNO 3 was added. The mixture was warmed up to room temperature and stirred at room temperature for 3 hours, was basified with 40% NaOH to pH>12 and then extracted with 2×11 CHCl 3 . The CHCl 3 extraction was back washed with 3×110.5 M NaOH and dried over 15 g K 2 CO 3 . The solvent was evaporated to afford 49.8 g orange oil (yield: 88%), which crystallized when cooled.
1 H-NMR (CDCl 3 ), δ (ppm): 1.30 (br.s, 2H), 2.80 (t, 2H), 2.95 (t, 2H), 3.80 (s, 3H), 3.92 (s, 3H), 6.90 (s, 1H), 7.20 (s, 1H).
2.1.2. N-t-butoxycarbonyl-4-nitro-2,5-dimethoxyphenethylamine (J3)
To a solution of 22.6 g (100 mmol) 4-nitro-2,5-dimethoxyphenethylamine J2 and 15.5 g (120 mmol) triethylamine in 125 ml CHCl 3 was added 26.2 g (120 mmol) di-t-butyl dicarbonate in 25 ml CHCl 3 . The mixture was stirred at room temperature for 15 min, washed with 3×200 ml 0.4 M HCl and dried over Na 2 SO 4 . The solvent was evaporated to give 36 g oil. This oil was dissolved in 20 ml ethyl acetate, then 200 ml hexane was added, the resultant precipitate was filtered, washed with 2×100 ml hexane and dried at room temperature for 18 hours to afford 27.4 g light yellow fibrous powder (yield: 84%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.40 (s, 9H), 2.82 (t, 2H), 3.35 (t, 2H), 3.80 (s, 3H), 3.90 (s, 3H1), 6.90 (s, 1H), 7.20 (s, 1H).
2.1.3. N-t-butoxycarbonyl-4-amino-2,5-dimethoxyphenethylamine (J4)
27 g (83 mmol) N-t-butoxycarbonyl-4-nitro-2,5-dimethoxyphenethylamine J3 was dissolved in 300 ml methanol, and 1.5 g 10% palladium on carbon black was added. This suspension was hydrogenated at 2.2 atm. for 18 hours till no further hydrogen uptake was observed. The catalyst was filtered off and the solvent was evaporated to afford 22.3 g white powder (yield: 98%). 1 H-NMR (CDCl 3 ), δ (ppm): 1.40 (s, 9H), 1.55 (s, 2H), 2.65 (t, 2H), 3.25 (t, 2H), 3.70 (s, 3H), 3.80 (s, 31H), 6.30 (s, 1H), 6.58 (s, 1H).
2.1.4. N-t-butoxycarbonyl-4-(N′-ethoxyethyl)amino-2,5-dimethoxyphenethylamine (J5)
A mixture of 11.9 g (40 mmol) J4, 5.2 g (48 mmol) chloroethyl ethyl ether M14 (see FIG. 2 B), 11.6 g (48 mmol) K 2 CO 3 , 4.0 g (24 mmol) KI and 20 ml DMF was heated at 95° C. for 18 hours. DMF was evaporated and the residue was dissolved in 200 ml CHCl 3 and 200 ml water. The organic layer was washed with 200 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 12 g oil. This oil was purified by a plug packed with 60 g silica gel 100 using cyclohexane as eluant, wherein 2.65 g pure product was obtained (yield: 18%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 3H), 1.40 (s, 9H), 1.55 (s, 2H), 2.65 (t, 2H), 3.30 (m, 4H), 3.55 (q, 2H), 3.65 (t, 2H), 3.70 (s, 3H), 3.80 (s, 3H), 4.45 (br.s, 1H), 4.70 (br.s, 1H), 6.25 (s, 1H), 6.55 (s, 1H).
2.1.5. 4-(N-ethoxyethyl)amino-2,5-dimethoxyphenethylamine (J6)
2.60 g (7.1 mmol) J5 was dissolved in a mixture of 10 ml trifluoroacetic acid and 1 ml water. The mixture was stirred at room temperature for 15 min, diluted with 20 ml water, basified with saturated K 2 CO 3 to pH˜12 and extracted with 2×40 ml CHCl 3 . The extraction was dried over K 2 CO 3 . The solvent was evaporated to afford 1.78 g oil (yield: 92%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (t, 3H), 1.60 (br. 2H), 2.65 (t, 2H), 2.90 (t, 3H), 3.30 (t, 2H), 2.90 (t, 3H), 3.30 (t, 2H), 3.55 (q, 2H), 3.70 (t, 2H), 3.80 (s, 3H), 3.85 (s, 3H), 4.45 (br.s, 1H), 6.30 (s, 1H), 6.60 (s, 1H).
2.1.6. 4-Chloro-1,8-naphthalimidylrnethylbenzoic acid (C2)
46.4 g (200 mmol) 4-chloro-1,8-naphthalic anhydride C1 and 30.2 g (200 mmol) 4-aminomethyl benzoic acid were suspended in 1 l DMF, stirred at room temperature for 16 hours and then at 60° C. for 6 hours. The mixture was poured into 3 l water and the pH adjusted to 4 with 6 N HCl. The resultant precipitate was filtered and dried at 60° C. for 18 hours to afford 36 g off-white powder (yield: 51%).
1 H-NMR (CDCl 3 ), δ (ppm): 5.30 (s, 2H), 7.45 (d, 2H), 7.85 (d, 2H), 8.02 (q, 2H), 8.45(d, 1H), 8.60 (t, 2H).
2.1.7. t-Butyl-4-chloro-1,8-naphthalimidyknethylbenzoate (C3)
To a suspension of 29.2 g (80 mmol) C2 in 320 ml DMF, stirred at 40° C. under a stream of nitrogen, 52.0 g (320 mmol) 1,1′-carbonyldiimidazole was added slowly during 20 min. The suspension turned into a clear solution and became turbid again in 15 min. Then the mixture was heated to 70° C. and after addition of 52 ml (1600 mmol) t-butanol and 48 ml (320 mmol) 1,8-diazabicyclo[5,4,0]undec-7-ene (DBU) was kept at this temperature for 18 hours. The mixture was cooled and poured into 2.0 l icy 1 N HCl under vigorous stirring. The resultant precipitate was filtered, washed with 2×300 ml 1 N HCl, and after drying in a desiccator with P 2 O 5 for 18 hours it afforded 28.5 g crude product. This crude product was purified with a silica gel column using CHCl 3 /cyclohexane as eluant to give 12.0 g white powder (yield: 36%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.50 (s, 9H), 5.30 (s, 2H), 7.45 (d, 2H), 7.80 (d, 2H), 8.05 (q, 2H), 8.50 (d, 1H), 8.60 (t, 2H).
2.1.8. t-Butyl 4-{4-[4-(N-ethoxyethylamino)-2,5-dimethoxyphenylethyl amino]-1,8-naphthalimidylmethyl} benzoate (J7)
A suspension of 1.70 g (6.3 mmol) J6 and 0.88 g (2.1 mmol) C3 in 2.2 ml N-methylpyrrolidinone (NMP) was heated at 85° C. for 18 hours. The mixture was cooled and poured into 45 ml water. The resultant precipitate was filtered and washed with 3×20 ml water and dried over P 2 O 5 for 18 hours to obtain 1.2 g crude product. The crude product was purified with a silica gel column using CHCl 3 as eluant to afford 0.92 g pure product (yield: 67%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.20 (t, 3H), 1.55 (s, 9H), 3.05 (t, 2H), 3.35 (t, 2H), 3.55 (m, 4H), 3.70 (t, 2H), 3.80 (s, 3H), 3.95 (s, 3H), 5.40 (s, 2H), 6.65 (t, 2H), 6.80 (t, 1H), 7.58 (m, 3H), 7.90 (d, 2H), 8.00 (d, 1H), 8.45 (d, 1H), 8.60 (d, 1H).
2.1.9. t-Butyl 4-{4-[4-(N-ethoxyethylamino)-4-(bis-ethoxycarbonylmethylaminoethyl)-2,5-dimethoxyphenylethylamino]-1,8-naphthalimidylmethyl} benzoate (J8)
A suspension of 0.90 g (1.38 mmol) J7, 1.23 g (4.41 mmol) M9 (see FIG. 2B) and 0.57 g (4.41 mmol) diisopropylethylamine in 5.5 ml DMF was heated at 90° C. for 20 hours under a nitrogen atmosphere (nitrogen balloon). Then 0.67 g (2.20 mmol) more M9 was added. The mixture was heated for another 18 hours. DMF was evaporated and the residue was dissolved in 50 ml CHCl 3 and 50 ml water. The organic phase was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 2.7 g brown oil.
This oil was purified on 13 g silica gel 100, using CHCl 3 as eluant to remove unreacted J7 and then using CHCl 3 /ethyl acetate (4/1, v/v), wherein 0.40 g of the pure desired product (yield: 32%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (m, 9H), 1.55 (s, 9H), 2.85 (t, 2H), 3.05 (t, 2H), 3.30 (s, 3H), 3.35 (t, 2H), 3.55 (m, 6H), 3.70 (t, 2H), 3.80 (s, 3H), 3.95 (s, 3H), 5.40 (s, 2H), 6.65 (t, 2H), 6.80 (t, 1H), 7.58 (m, 3H), 7.90 (d, 2H), 8.00 (d, 1H), 8.45 (d, 1H), 8.60 (d, 1H).
FABMS (70 eV, m-nitrobenzyl alcohol dispersion with LiI): 876 (77%), (M+Li); 710 (100%), (dealkylated luminophore-ionophore).
Calcd. for C 42 H 49 N 3 O 13 : C 66.36; H 6.96; N 6.45; Found: C 65.68; H 7.08; N 6.35.
2.1.10. 4-{4-[4-(N-ethoxyethylamino)-4-(bis-ethoxycarbonylmethyl-aminoethyl)-2,5-dimethoxyphenylethylamino]-1,8-naphthalimidylmethyl}-benzoic acid (J9)
2 ml trifluoroacetic acid (TFA) was added to a solution of 0.40 g (0.46 mmol) J8 in 8 ml CH 2 Cl 2 . The resultant solution was stirred at room temperature for about 1 hour, till the TLC indicated that most of the J8 had been hydrolyzed. The mixture was diluted with 20 ml CHCl 3 and evaporated. The residue was dissolved in 20 ml CHCl 3 and evaporated again. The process was repeated two more times in order to remove the TFA completely, whereupon 0.36 g gum was obtained (yield: 95%). This was directly used for immobilization.
2.1.1 1. Immobilization of 4-{4-[4-(N-ethoxyethylamino)-4-(bis-ethoxycarbonylmethyl-aminoethyl)-2,5-dimethoxyphenylethylamino]-1,8-naphthalimidylmethyl } benzoic acid on aminocellulose (J10)
0.36 g (0.45 mmol) of indicator J9, 0.93 g (4.5 mmol) N,N-dicyclohexyl-1,3-carbodiimide, 0.52 g (4.5 mmol) N-hydroxysuccinimide and 10 g (˜3 meq.) activated cellulose (prepared according to SU-A-1 028 677, CA 99:177723h) were suspended in 50 ml DMF for 20 hours. The cellulose fiber was filtered and washed with 5×50 ml DMF, 50 ml water, 2×50 ml 0.2 N HCl, 50 ml water, 2×50 ml 0.2 N NaOH and 10×50 ml water. The resultant fiber was ready for hydrolysis.
2.1.12. Hydrolysis of 4-{4-[4-(N-ethoxyethylamino)-4-(bis-ethoxycarbonylmethylaminoethyl)-2,5-dimethoxyphenylethylamino]-1,8-naphthalimidylmethyl} benzoic acid immobilized on aminocellulose to free the carboxyl groups for calcium binding (J11)
The cellulose powder with immobilized indicator (J10) prepared in the previous step was suspended in 50 ml 1 N KOH. The suspension was heated to 80° C. for 5 min, stirred at room temperature for 3 hours, filtered and washed with 20×50 ml water till the filtrate became neutral. Then it was washed with 2×50 ml acetone and 2×50 ml ether and dried at room temperature for 16 hours prior to testing.
2.2. Synthesis of a luminophore-ionophore using X7* as ionophore
2.2.1. 2,5-Diethoxybenzaldehyde (N3)
A suspension of 9.66 g (70 mmol) 2,5-dihydroxybenzaldehyde N2, 32.75 g (210 mmol) iodoethane, 24.19 g (175 mmol) K 2 CO 3 in 350 ml acetone was heated to reflux for 18 hours under nitrogen. The solvent was evaporated and the residue was dissolved in 300 ml CHCl 3 and 300 ml water. The organic phase was washed with 2×300 ml 2.5% Na 2 CO 3 and 300 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated and the residue (13.5 g) purified with a silica gel column (silica gel 100, CHCl 3 /cyclohexane: 1/1, v/v), affording 8.61 g light yellow oil, which crystallized after cooling to room temperature (yield. 63%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.38 (t, 3H), 1.42 (t, 3H), 4.00 (q, 2H), 4.10 (q, 2H), 6.90 (d, 1H), 7.10 (d, 1H), 7.30 (s, 1H), 10.45 (s, 1H).
2.2.2. 2,5-Diethoxy-β-nitrostyrene (N4)
A mixture of 8.35 g (43 mmol) N3, 26.24 g (430 mmol) nitromethane, 33.10 g (430 mmol) ammonium acetate in 86 ml acetic acid was warmed slowly to 80° C. and kept at this temperature for 2 hours. After cooling to room temperature, the mixture was poured into 800 ml icy water. The resultant precipitate was filtered, washed with 3×100 ml water and dried over P 2 O 5 for 18 hours, wherein 8.15 g yellow prisms were obtained (yield: 80%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.40 (t, 3H), 1.50 (t, 3H), 4.00 (q, 2H), 4.12 (q, 2H), 6.85 (d, 1H), 6.96 (m, 2H), 7.84 (d, 1H), 8.60 (d, 1H).
2.2.3. 2,5-Diethoxyphenethylamine (N5)
A solution of 8.00 g (33.7 mmol) N4 in 50 ml THF was added slowly into a suspension of 13.37 g (337 mmol) lithium aluminum hydride in 500 ml THF at boiling temperature during 1 hour. The mixture was heated to reflux for another 4 hours. The mixture was then cooled with ice-water bath to ˜15° C. and quenched with 18% NaOH. The precipitate was filtered off, the filtrate evaporated to dryness and the residue dissolved in 50 ml CHCl 3 . This solution was extracted with 2×50 ml 1 N HCl. The aqueous extracts were basified with 40% NaOH to pH>12 and then extracted with 2×50 ml CHCl 3 and dried over K 2 CO 3 . The solvent was evaporated to afford 5.80 g light yellow oil (yield: 84%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.40 (t, 6H), 1.80 (br.s, 2H), 2.75 (t, 2H), 2.95 (t, 2H), 4.00 (q, 4H), 6.75 (m, 3H).
2.2.4. 4-Nitro-2,5-diethoxyphenethylamine (N6)
5.23 g (25 mmol) 2,5-diethoxyphenethylamine N5 was mixed with 10 ml water and cooled to 0° C. while 3 ml conc. HCl was added slowly. The resultant milky emulsion was to cooled 0 to 5° C. and 13.5 ml conc. HNO 3 was added slowly and carefully within about 2 hours. The temperature was kept below 10° C. The mixture solidified when about half of the HNO 3 had been added. 50 ml icy water was added to render the mixture stirrable. Then the rest of the HNO 3 was added. The mixture was warmed up to room temperature and stirred at room temperature for 3 hours, basified to pH>12 with 40% NaOH and then extracted with 2×100 ml CHCl 3 . The CHCl 3 extraction was back washed with 3×100 ml 0.5 M NaOH and dried over 10 g K 2 CO 3 . The solvent was evaporated to afford 3.22 g orange oil (yield: 52%), which crystallized when cool.
1 H-NMR (CDCl 3 ), δ (ppm): 1.40 (m, 6H), 1.75 (br.s, 2H), 2.80 (t, 2H), 2.95 (t, 2H), 4.05 (q, 2H), 4.15 (q, 2H), 6.90 (s, 1H), 7.40 (s, 1H).
2.2.5. 4-Amino-2,5-diethoxyphenethylamine (N7)
3.05 g (12.0 mmol) 4-nitro-2,5-diethoxyphenethylamine N6 was dissolved in 50 ml ethanol, and 1.5 g 10% palladium on carbon black was added. This suspension was hydrogenated at 2.2 atm. for 18 hours, till no more hydrogen uptake was observed. The catalyst was filtered off and the solvent was evaporated to afford 2.75 g light yellow oil (yield: 102%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (m, 6H), 1.40 (br.t, 4H), 2.90 (t, 2H), 3.20 (t, 2H), 3.75 (q, 2H), 3.95 (m, 2H), 6.30 (s, 1H), 6.65 (s, 1H).
2.2.6. t-Butyl 4-[4-(4-amino-2,5-diethoxyphenylethylamino)-1,8-naphthalimidylmethyl]-benzoate (N8)
A suspension of 2.70 g (12.0 mmol) N7 and 1.68 g (4 mmol) C3 (see 2.1.7. and FIG. 3A) in 6 ml N-methylpyrrolidinone (NMP) was heated at 85° C. for 5 hours. The mixture was cooled and poured into 114 ml water. The resultant precipitate was filtered off, washed with 3×20 ml water and dried over P 2 O 5 for 18 hours, wherein 1.9 g crude product was obtained. The crude product was purified with a silica gel column using CHCl 3 as eluant to afford 0.47 g pure product (yield: 19%).
1 H-NNR (CDCl 3 ), δ (ppm): 1.35 (t, 3H), 1.45 (t, 3H), 1.55 (s, 9H), 3.10 (t, 2H), 3.60 (t, 2H), 3.98 (q, 2H), 4.12 (q, 2H), 5.40 (s, 2H), 6.75 (m, 1H), 7.58 (m, 3H), 7.90 (d, 2H), 8.00 (d, 1H), 8.45 (d, 1H), 8.60 (d, 1H).
2.2.7. t-Butyl 4-{4-[4-(bis-ethoxycarbonylmethoxyethylamino)-2,5-diethoxyphenylethylamino]-1,8-naphthalimidylmethyl } benzoate (N9)
A suspension of 0.46 g (0.75 mmol) N8, 0.50 g (3 mmol) M25 (for synthesis see 1.7. and FIG. 2 C), 0.42 g (3 mmol) K 2 CO 3 and 0.25 g (1.5 mmol) KI in 5 ml DMF was heated at 83° C. for 20 hours under a nitrogen atmosphere (nitrogen balloon). Then 0.50 g (2.20 mmol) more M25 and 0.42 g more K 2 CO 3 were added. The mixture was heated for another 18 hours. DMF was evaporated and the residue was dissolved in 50 ml CHCl 3 and 50 ml water. The organic phase was washed with 50 ml saturated NaCl and dried over Na 2 SO 4 . The solvent was evaporated to give 1.27 g brown oil. This oil was purified on 13 g silica gel 100, using CHCl 3 as eluant to remove unreacted N8 and then using CHCl 3 /ethyl acetate (4/1, v/v). 0.23 g of the desired pure product was obtained (yield: 35%).
1 H-NMR (CDCl 3 ), δ (ppm): 1.25 (m, 9H), 1.55 (s, 9H), 2.85 (t, 2H), 3.05 (t, 2H), 3.30 (s, 3H), 3.35 (t, 2H), 3.55 (m, 6H), 3.70 (t, 2H), 3.80 (s, 3H), 3.95 (s, 3H), 5.40 (s, 2H), 6.65 (t, 2H), 6.80 (t, 1H), 7.58 (m, 3H), 7.90 (d, 2H), 8.00 (d, 1H), 8.45 (d, 1H), 8.60 (d, 1H).
2.2.8. 4-{4-[4-(Bis-ethoxycarbonylmethoxyethylamino)-2,5-diethoxyphenylethylamino]-1,8-naphthalimidylmethyl} benzoic acid (N10)
1 ml Trifluoroacetic acid (TFA) was added into a solution of 0.20 g (0.23 mmol) N9 in 4 ml CH 2 Cl 2 . The resultant solution was stirred at room temperature for about 1 hour when the TLC indicated that most of N9 was hydrolyzed. The mixture was diluted with 20 ml CHCl 3 and evaporated. The residue was dissolved in 20 ml CHCl 3 and evaporated again. The process was repeated two more times in order to remove TFA completely, whereupon 0.18 g gum was obtained (yield: 95%). This was used directly for immobilization.
2.2.9. Immobilization of 4-{4-[4-(bis-ethoxycarbonylmethoxyethylamino)-2,5-diethoxy-phenylethylamino]-1,8-naphthalimidylmethyl} benzoic acid on aminocellulose (N11)
0.18 g (0.23 mmol) of N10, 0.46 g (2.3 mmol) N,N-dicyclohexyl-1,3-carbodiimide, 0.26 g (2.3 mmol) N-hydroxysuccinimide and 5 g (˜1.5 meq.) activated cellulose (prepared according to SU-A-1 028 677, CA 99:177723h) were suspended in 50 ml DMF for 20 hours. The cellulose fiber was filtered and washed with 5×50 ml DMF, 50 ml water, 2×50 ml 0.2 N HCl, 50 ml water, 2×50 ml 0.2 N NaOH and 10×50 ml water. The resultant fiber was ready for hydrolysis.
2.2.10. Hydrolysis of 4-{4-[4-(Bis-ethoxycarbonylmethoxyethylamino)-2,5-diethoxyphenylethylamino]-1,8-naphthalimidylmethyl} benzoic acid immobilized on aminocellulose to free the carboxyl groups for calcium binding (N12)
The cellulose powder with immobilized indicator (N11) prepared in the previous step was suspended in 50 ml 1 N KOH. The suspension was heated to 80° C. for 5 min, stirred at room temperature for 3 hours, filtered, and the precipitate washed with 20×50 ml water, till the filtrate became neutral. Then it was washed with 2×50 ml acetone and 2×50 ml ether and dried at room temperature for 16 hours prior to testing.
3. Preparation of optical sensors (sensor discs) of the invention
0.5 g sieved (25-μm) aminocellulose fibers with immobilized indicator J11 (X3*), which had been prepared as described in Section 2.1.12, was suspended in 9.5 g 10% hydrogel D4 (Tyndale Plains-Hunter LTD. Ringoes, N.J. 08551) in 90% ethanol-water for 16 hours. The resultant homogeneous dispersion was coated onto a polyester foil (Melinex foil, ICI America) with a final dry thickness of 10 μm. This foil was overcoated with 3% carbon black in 10% D4 hydrogel in 90% ethanol-water with a final dry thickness of 5 μm. Then a small disc 2.5 cm in diameter was punched out and soaked in buffer for at least 16 hours for activation.
The same procedure was also used for preparing sensor discs comprising immobilized indicators using X2* or X7* (=N12) as the ionophoric moiety.
4. Determination of the K d values of ionophores of the invention
4.1. Determination of the absorption properties of ionophores of the invention
FIG. 4 shows the relative absorption values (Ca 2+ titration curves) of ionophores X1 to X9 of the invention represented in FIG. 1 in aqueous solution (30 mmol/l tris/HCl buffer; CO 2 -free; pH 7.4) in dependence on the concentration of Ca 2+ (0.00001 to 0.5 mol/l Ca 2+ ) at an absorption wavelength of 248 nm.
The absorption values in dependence on the Ca 2+ concentration were measured using a commercial photometer, at an absorption wavelength of 248 nm. The resulting titration curves were normalized to the value A max =1 at a Ca 2+ concentration of 0.00001 mol/l using Equation 4 (see below).
4.2 Determination of the K d values of the ionophores
The K d values of the ionophores were determined from the measured absorption values of the Ca 2+ -titration curves according to Equation 3 (see above) and Equation 4 A x = A max ( 1 + Q - 1 1 - 10 ( pKd - log ( c Ca ) ) ) , ( 4 )
wherein A x is the normalized absorption value at the given Ca 2+ concentration, A max is the absorption value at 0.00001 mol/l Ca 2+ and pK d has the meaning indicated in Equation 3. Parameter Q allows for the fact that the absorption values at high Ca 2+ concentrations do not approach zero.
The K d values for ionophores X1 to X9 of the invention are given in Table 1. They were determined from the found pK d values by means of Equation 3.
TABLE 1
Ionophore
K d (mol/l)
Group 1)
X1
0.123
I
X2
0.00033
I
X3
0.00104
I
X4
0.00914
I
X5
0.00696
I
X6
0.00020
II
X7
0.00109
II
X8
0.00072
II
X9
0.00616
III
1) Ionophores of Group I have a group of the general Formula II.
Ionophores of Group II have a group of the general Formula III.
Ionophores of Group III have a group of the general Formula IV.
Group I:
In the ionophores of the invention of Group I, the imino-N,N-diacetate ligands are bound to the nitrogen atom of the o-alkoxyaniline by means of a —CH 2 —CY— group (Y=H 2 or O).
By a suitable choice of the substituents R 1 on the nitrogen atom and/or R 2 on the oxygen atom and/or R 3 on the aromatic ring of the o-anisidine, the K d value of the ionophore can be adjusted. For ionophores with Y=H 2 , for example K d values of 0.1-10 mmol/l can be adjusted (see Table 1: X2 to X5). Compounds with Y=O are suitable for the determination of particularly high Ca 2+ concentrations (>10 mmol/l) (see Table 1: X1).
Suitable substituents R 1 are for example methoxyethyl (X1 and X2), ethoxyethyl (X3), phenoxyethyl (X5) or n-butyl (X4). Suitable substituents R 2 are for example methyl (X2 to X5), ethyl or propyl. Suitable substituents R 3 on the aromatic ring are electron-withdrawing or electron-donating (for example H, X1 to X5) groups.
Group II:
The ionophores of the invention of Group II have alkyloxyacetate groups (—(CH 2 ) n —O—CH 2 —COOH) in the ligand portion, which are bound to the nitrogen atom of the o-alkoxyaniline. n is preferably 2, for example in compounds X6 to X8. As in the ionophores of Group I, the K d values can be adjusted by varying the substituents R 4 on the oxygen atom (cf. for example the K d values for X6 and X7 in Table 1) and/or by inserting electron-withdrawing or electron-donating groups R 5 on the aromatic ring of the o-alkoxyaniline.
Suitable substituents R 4 are for example methyl (X6 and X8) or ethyl (X7). A suitable electron-donating group is for example H (X6, X7), a suitable electron-withdrawing group R 5 is for example Cl (X8).
Group III:
In the ionophores of the invention of Group III, the imino-N,N-diacetate ligand portion is bound by means of a —CH 2 —CH 2 — group on the oxygen atom of the o-alkoxyaniline. The nitrogen atom carries two alkoxyethyl or phenoxyethyl groups. Also in this group of compounds the K d values are adjustable by varying the residues. A suitable substituent R 6 is for example methyl (X9). Suitable substituents R 7 are electron-withdrawing or electron-donating (for example H in X9) groups.
5. Determination of the luminescence properties of luminophore-ionophores of the invention
In order to measure the luminescence intensity of some compounds of the invention (luminophore-ionophores), sensor discs prepared according to the process described above (see Section 3.) were introduced into a light-transmitting thermostatted measuring cell and brought into contact with samples P (see FIG. 5) exhibiting different concentrations of Ca 2+ and different pH values.
The measuring arrangement is represented schematically in FIG. 5, with a portion of the sensor disc being denoted by S. The compound of the invention suspended in the hydrophilic ion-permeable polymer (hydrogel) and immobilized on aminocellulose is denoted by I. This layer M is carried by a substrate T permeable to excitation and measuring radiation, which is a transparent foil.
The optical measuring system consisted of a blue LED as the light source L, a photodiode M as the detector, optical filters A and F for selecting the wavelengths, a fiber-optic arrangement for conducting the excitation light into the polymer layer M and for conducting the emission light to the photodetector M as well as a device for electromagnetic signal processing (not illustrated). At the excitation end there was utilized an interference filter peak transmission at 480 nm) and at the emission end a 520 nmu cut-off filter.
FIGS. 6 and 7 show the luminescence properties of some compounds of the invention, immobilized on cellulose, as a function of the concentration of Ca 2+ and of the pH, respectively. In each Figure, the ordinates of the illustrated diagrams give the relative luminescence intensities.
FIG. 6 :
FIG. 6 shows the relative luminescence intensity of three luminophore-ionophores of the invention (L-X2*, L-X3*=J11, L-X7*=N12), immobilized on aminocellulose, as a function of the negative common logarithm of the calcium concentration (0.0002, 0.0004, 0.0006, 0.0009, 0.0011, 0.0013, 0.0015, 0.0017, 0.0020, 0.0022, 0.0024 mol/l).
The measuring media that were used were 0.1 M HEPES buffers, CO 2 -free, pH 7.4 (37° C.), with different concentrations of CaCl 2 .
FIG. 7 :
FIG. 7 shows the relative luminescence intensity of two luminophore-ionophores of the invention (L-X3*=J11, L-X7*=N12), immobilized on aminocellulose, as a function of the pH (6.841, 6.932, 7.030, 7.149, 7.271, 7.396, 7.507, 7.603, 7.700).
The measuring media that were used were 0.1 M HEPES buffers with different concentrations of HEPES acid and HEPES-Na salt and a concentration of CaCl 2 of 0.0013 mol/l.
As can be seen from FIG. 7, ionophores or luminophore-ionophores of the invention having an ethyl-imino-N,N-diacetate ligand portion (Group 1, Y=H 2 ) which is bound to the nitrogen of the o-anisidine show pH-dependence at physiological pH values. They are thus suitable for those measuring situations where the pH of the sample is known or can be adjusted to a known value (e.g. by pH buffers).
Further it can be seen from FIG. 7 that ionophores or luminophore-ionophores of the invention having a diethoxyacetate ligand portion bound to the nitrogen of the o-anisidine in view of their non-significant pH-dependence in the physiological pH measuring range are particularly suited for determining Ca 2+ at a physiological pH.
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The invention relates to a compound having the general Formula I:
including its salts, where Z is either the group having the general Formula II:
where
R 1 is alkyl having 1-4 C atoms, alkoxyalkyl having 2-5 C atoms or aryloxyalkyl whose alkyl group has 1-4 C atoms,
R 2 is alkyl having 1-4 C atoms or alkoxyalkyl having 2-5 C atoms,
R 3 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 ,
Y is H 2 or O and
L is a luminophoric moiety in a position para or meta to the nitrogen,
or is the group having the general Formula III:
where
n is 2 or 3,
R 4 is alkyl having 1-4 C atoms or alkoxyalkyl having 2-5 C atoms,
R 5 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 and
L is a luminophoric moiety in a position para or meta to the nitrogen,
or is the group having the general Formula IV:
where
R 6 is alkyl having 1-3 C atoms or phenyl,
R 7 is H, alkoxy having 1-4 C atoms, halogen, NO or NO 2 and
L is a luminophoric moiety in a position para or meta to the nitrogen.
The compound of the invention can be used as a luminescence indicator for the determination of calcium ions in a sample.
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