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CROSS-REFERENCE TO PRIOR APPLICATION
[0001] Priority is claimed from U.S. Provisional Application Serial No. 60/420,661, filed Oct. 23, 2002, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the field of heating units, especially heating units intended for use in processes requiring precisely-controlled amounts of heat.
[0003] The present invention is an improvement over the circuits described in U.S. Pat. No. 6,100,510, the disclosure of which is incorporated by reference herein. The cited patent discloses a bridge circuit, in which a heating element comprises one arm of the bridge. The present invention can be used in essentially the same environment, and for the same purpose, as the circuit shown in the cited patent.
[0004] An important aspect of the invention described and claimed in U.S. Pat. No. 6,100,510 is the limitation of the sensing period duty cycle, thereby reducing unwanted heat generated by the sensing current. The circuit described in the above-cited patent samples heater resistance every 16.6 milliseconds, and is commercially useful with heater element materials having positive temperature coefficient (PTC) values as low as about 500 PPM.
[0005] The present invention has resulted in significant improvements to the original circuit described in the above-cited patent. These improvements further reduce the sensing circuit duty cycle, which reduces dissipated heat even further than in the original circuit. In turn, a short duty cycle allows the use of very high peak sensing currents, which permit the circuit to operate with heating element materials having PTC values as low as 50 PPM.
[0006] In another embodiment of the present invention, quad comparator circuitry has been devised that provides sampling rates of either 16.6 ms or 8.3 ms, and also allows the sensing period to be more precisely tailored.
[0007] In still another embodiment, switching circuitry is provided whose performance approaches that of the quad comparator circuitry, while using fewer components than are required by the quad comparator. In particular, the circuit of the present invention provides sensing pulses having an amplitude which is relatively unaffected by changes in line voltage.
SUMMARY OF THE INVENTION
[0008] The present invention provides an improvement to the heating unit described in the above-identified patent. The heating unit includes a bridge circuit, in which a heating element comprises one arm of the bridge. The circuits of the present invention make it possible not only to reduce the duty cycle of sensing current used in such units, but to control precisely the start and stop points of the sensing pulses.
[0009] In one embodiment, the circuit of the present invention uses zener diodes which cause the sensing current pulses to start and stop at desired voltages. In another embodiment, the circuit uses a quad comparator which provides the electronic logic for starting and stopping the sensing current pulses at predetermined points in a cycle.
[0010] In several of the preferred embodiments, an optocoupler is connected to a switch which generates sensing pulses, the optocoupler receiving current through an RC network that effectively speeds the current flow through the optocoupler, thereby making it practical to generate sensing pulses of very short duration. The same improvement also tends to make the circuit less dependent on supply voltage, enabling the circuit to generate sensing pulses having an amplitude which is essentially unaffected by variations in supply voltage.
[0011] Another preferred embodiment uses a SIDAC instead of one of the zener diodes. The SIDAC provides rapid turn-on of the sensing pulse, and therefore aids further in providing narrow sensing pulses, and in making the circuit less sensitive to variations in supply voltage.
[0012] The invention also includes the method of operating the control device described above. The essence of the method is the generation of sensing pulses, wherein each pulse is relatively narrow, and wherein each pulse, in general, begins substantially after the beginning of a half-cycle of the supply voltage, i.e. a substantial time following the zero crossing point. The start and stop points of the pulses are selected so as to provide sensing pulses having sufficient amplitude and duration to perform their intended function, and also so that the amplitude of the pulses is relatively unaffected by variations in supply voltage.
[0013] The method and circuit of the present invention make it practical to use sensing pulses as narrow as about 150 microseconds.
[0014] The invention therefore has the primary object of reducing the duty cycle of sensing current pulses, used in heating devices for supplying a precise amount of heat in response to a sensed temperature.
[0015] The invention has the further object of improving the efficiency of circuits described above, by reducing the amount of unwanted heat generated by the sensing current.
[0016] The invention has the further object of enabling the use of higher peak sensing currents, so as to permit operation with heating elements having very small temperature coefficients.
[0017] The invention has the further object of providing sensing pulses which can be adjusted to be either wide or narrow, and which can have leading and trailing edges which are essentially vertical, for use as described above.
[0018] The invention has the further object of providing sensing pulses as described above, wherein the amplitude of the sensing pulses is relatively unaffected by variations in supply voltage.
[0019] The reader skilled in the art will recognize other objects and advantages of the present invention, from a reading of the following brief description of the drawings, the detailed description of the invention, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 provides a schematic diagram of a current reduction circuit of the prior art.
[0021] [0021]FIG. 2 provides a diagram of a waveform, showing the character of the sensing period according to the prior art circuit of FIG. 1.
[0022] [0022]FIG. 3 provides a schematic diagram of a current reduction circuit made according to a first embodiment of the present invention, wherein zener diodes are used to control the start and stop points of the sensing period.
[0023] [0023]FIG. 4 provides a diagram of a waveform, illustrating the control of sensing period according to the circuit of FIG. 3.
[0024] [0024]FIG. 5 provides a schematic diagram of a circuit made according to an alternative embodiment of the present invention, wherein a quad comparator is used to control the start and stop points of the sensing period. The figure also includes pulse diagrams which illustrate the voltages at the various comparators.
[0025] [0025]FIG. 6 provides a schematic diagram, showing the integration of the circuit of FIG. 5 into a circuit for controlling a heating unit.
[0026] [0026]FIG. 7 provides a diagram of a waveform, illustrating the control of the sensing period according to the circuits of FIGS. 5 and 6.
[0027] [0027]FIG. 8 provides a schematic diagram of a current reduction circuit made according to another alternative embodiment of the invention, this embodiment using zener diodes to control the start and stop points of the sensing period.
[0028] [0028]FIG. 9 provides a schematic diagram of a current reduction circuit made according to another alternative embodiment of the invention, wherein one of the zener diodes is replaced with a SIDAC.
[0029] [0029]FIG. 10 provides a waveform diagram, illustrating the shape of a typical sensing pulse produced by a current reduction circuit controlled by a zener diode, according to the present invention.
[0030] [0030]FIG. 11 provides a graph showing changes in the delay angle of the start of the sensing pulse, for different values of supply voltage, obtained from the current reduction circuit of the present invention.
[0031] FIGS. 12 - 15 provide waveform diagrams showing the sensing pulses produced by the circuit of the present invention, for different values of supply voltage, the diagrams showing that the amplitude of the sensing pulse is relatively unaffected by changes in supply voltage. Each of these figures also includes a timing diagram, showing the electrical angle associated with various critical points on the basic waveform.
[0032] [0032]FIG. 16 provides a schematic diagram of a bridge circuit of the prior art, the bridge circuit including a current reduction circuit which is the subject of the improvements described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0033] In the drawings, some of the components are labeled with values and with component types. These values and component types should be considered exemplary and not limiting. Actual values, and component types, may be varied according to the needs of a particular application, as will be appreciated by those skilled in the art. For example, changing the design supply voltage is likely to require corresponding changes in one or more values of the components shown.
[0034] [0034]FIGS. 1 and 16 provide schematic diagrams of the original circuit covered by U.S. Pat. No. 6,100,510. The circuit of the cited patent is a bridge circuit, in which the heating element is an arm of the bridge. The ultimate object of the bridge circuit is to apply current to the heating element, so as to control precisely the temperature of that element. A further object is to do so in a manner such that the control circuitry does not itself unduly heat the heating element or the control circuit components. These objects are best satisfied when the sensing current is provided in the form of short-duration pulses. The above-cited patent therefore shows circuitry for generating such sensing pulses.
[0035] [0035]FIG. 16, which is similar to FIG. 2 of the above-cited patent, shows a bridge circuit, in which one arm is a heating element RH, and in which there is included a control circuit for providing narrow sensing pulses. For purposes of clarity, this control circuit is shown, in isolated form, in FIG. 1 of the present disclosure. In brief, the sensing pulses are generated by switch Q 1 , which in turn is controlled by optocoupler U 2 .
[0036] The circuit represented in FIG. 1 is known as a current reduction circuit, because an object of the circuit is to reduce the amount of sensing current in the bridge, by providing narrow pulses. The improvements of the present invention all relate to this current reduction circuit, which, in this disclosure, is also called a “CRC”.
[0037] The circuit shown in FIG. 1 produces the sensing period characterized by the waveform diagram of FIG. 2. The sensing begins essentially at the beginning of each positive waveform zero cross point, and may extend into the waveform up to 60 degrees. In order for the circuit of FIG. 1 to reset, capacitor C 5 must be completely discharged by energy applied to it during the waveform's opposite half cycle.
[0038] The majority of commercial heating element resistance alloys exhibit high resistivity, but generally offer positive temperature coefficient (PTC) values below 200 PPM, which is very low. The temperature coefficient, which can be defined as the change in heater resistance (in ohms) per ohm of heater resistance per degree C., is conveniently scaled by dividing by 10 −6 (or, equivalently, by multiplying by 10 6 ), so that the result can be expressed in “parts per million” (PPM).
[0039] Low PTC materials are difficult to use with known control methods that directly sense changes in heating element resistance, including that covered by the above-cited patent. Low PTC element alloys demand very high sensing current in order to generate acceptable sensing signals. This need, combined with the sensing period used by known commercial circuits, produces unacceptable amounts of heat from some circuit components. The only practical way to reduce unwanted heat is to shorten the sensing period, because any decrease in sensing current will degrade the sensing signal produced.
[0040] [0040]FIG. 3 shows one simple way to accomplish sensing periods shorter than those described in U.S. Pat. No. 6,100,510. A zener diode Z 3 is inserted in one power supply leg feeding the CRC. Zener diode Z 3 is inserted downstream from R 11 . Zener diode Z 3 prevents the CRC from becoming active until the supply waveform reaches zener voltage. The effect is shown in the waveform diagram of FIG. 4. The sensing period is now forced to begin long after the zero crossing point of the waveform. A shortened duty cycle is produced when the zener voltage of Z 1 is adjusted downward to limit the charging time allowed C 5 . Thus, Z 3 controls the turn-on point, and Z 1 controls the turn-off point, so that the these components respectively control the start and stop points of the sensing pulses.
[0041] Shortening the duty cycle allows peak sensing current to be substantially increased so that the control circuit can be used with some low PTC alloys. The method is both economical and effective for many commercial applications. The method has been found to have some performance limitations imposed by component availability and tolerance issues, but is still quite useful.
[0042] A more sophisticated approach is shown in FIGS. 5 and 6. FIG. 5 is a pulser schematic and FIG. 6 is very similar to FIG. 5, but it also shows the integration of the circuit into the control circuitry of U.S. Pat. No. 6,100,510. This circuitry is voltage-based. A quad comparator is used to generate signal pulses that operate the optocoupler U 2 , which, in turn, switches Q 1 , which is the switch that provides sensing current to the heating element. The comparator-based pulser circuit allows precise tailoring of sensing period characteristics over a wide range. That is, with the circuit of FIGS. 5 and 6, one can precisely control the point at which one starts the sensing current pulse, and the point at which the sensing current pulse is terminated. The circuit of the present invention can be used to create a sensing pulse having any desired width. Moreover, the latter can be achieved for a wide variety of power supply voltages.
[0043] Unlike the embodiment of FIG. 3, the embodiment of FIGS. 5 and 6 does not use zener diodes to control the point at which the sensing period begins and ends. Instead, the embodiment of FIGS. 5 and 6 uses a quad comparator, which is substituted for the circuit comprising R 11 , Z 3 , C 5 , D 5 , Z 1 , R 14 , D 7 , and D 8 of FIG. 3. The quad comparator accurately generates a signal that causes U 2 to trigger Q 1 as desired.
[0044] The quad comparator pulse generator produces a programmable and stable sensing pulse based on three absolute AC line voltage trip points. These trip points may be parametrically adjusted by changing a group of resistor values. The trip points are chosen to provide an optimum heater temperature sensing current.
[0045] The operation of the circuit will be described below, with reference to the schematic diagram of FIG. 5. The input AC line voltage is full wave rectified by diodes D 102 -D 105 . The resulting waveform is amplitude scaled by R 110 and R 111 such that the peak AC line voltage is reduced to +5 VDC at the input to comparators U 1 A and U 1 B. This is used as the reference for the start and stop comparators. The full wave rectified AC is also used to produce a regulated 5 VDC logic supply that operates the circuitry. The power supply comprises D 109 , R 114 , D 101 , C 101 , U 102 , C 102 , and C 103 .
[0046] The start comparator (U 1 B), produces a pulse that rises on the rising portion of the AC line waveform and falls on the falling portion of the AC line waveform when the AC line voltage reaches the start trigger voltage. The positive going edge of this pulse corresponds to the start of the sensing period. Resistors R 106 and R 107 set the reference point for this comparison against the scaled AC input. The stop comparator (U 1 A) has two voltage trip points. These two points are independently adjustable due to the use of hysteresis in the comparator circuit. The first output edge of the comparator is falling edge triggered at the rising portion of the AC line waveform trip point. This represents the end of the sensing period and must be set higher in value than the start trip point for proper circuit operation. The second trip point is set to lock out the circuit from false triggering on falling portion of the rectified AC line waveform. This trip point must be set to a lower voltage than the start trip point.
[0047] A third comparator (U 1 D) is used as a buffer for the stop comparator (for circuit isolation) and also provides a logical OR function. The start and stop pulses described earlier are combined in a logical OR operation. The resulting pulse edge rises at the start trip point and falls at the stop trip point.
[0048] Finally, a fourth comparator inverts the logic of this sensing pulse and drives the LED in the opto-isolator used for producing the actual sensing pulse.
[0049] When a full wave input bridge is used, the pulse is generated on each half cycle of the AC line voltage waveform. If a half wave bridge is used (by removing D 103 and D 105 , and replacing D 104 by a jumper), the pulse will only occur once each AC line voltage cycle. This allows both 1× and 2× line frequency sensing pulses. The two trip points do not change as the AC line voltage is varied as long as the peak AC line voltage is greater than the stop trip point. This stabilizes the temperature controller against shifts in set point due to line voltage variations.
[0050] The circuit of the present invention is also highly tolerant of variations in supply voltage and does not require exposure to a reverse polarity half wave to reset. These attributes not only allow minimal sensing periods, but also make it possible to construct a control that has an 8.3 ms sampling rate.
[0051] Control output waveforms for a 16.6 ms sampling rate are shown in FIG. 4. FIG. 7 displays control output waveforms for the 8.3 ms sampling rate. In the embodiment having an 8.3 ms sampling rate, the control must be supplied with pulsating DC from a full wave bridge rectifier of adequate ampacity to drive both the control and its heating load.
[0052] [0052]FIG. 8 provides a schematic diagram of an alternative and further improved embodiment of the CRC of the present invention. This embodiment is an improvement on FIG. 3. While the quad comparator circuitry of FIGS. 5 and 6 performs very well, it has the disadvantage that it requires a larger number of components. The aim of the circuit of FIG. 8 is to improve the circuit of FIG. 3, while still limiting the number of required components.
[0053] The circuit of FIG. 8 makes it still easier to generate narrow sensing pulses, and further enhances the ability of the current reduction circuit to generate sensing pulses that are relatively unaffected by changes in supply voltage.
[0054] The difference between the embodiment of FIG. 8 and that of FIG. 3 is in the addition of capacitor C 10 , connected across R 15 . At high AC frequencies, capacitor C 10 becomes essentially a short-circuit for alternating current, and therefore allows optocoupler U 2 to reach a full-current state very quickly. This feature, in turn, means that switch Q 1 , which provides sensing current to the heating element, is turned on more quickly. Thus, the leading edge of the sensing pulse becomes nearly vertical. That is why the addition of capacitor C 10 assists in generating narrow pulses with a near vertical leading edge.
[0055] Capacitor C 10 also helps to make the turn-on point of the sensing pulse more voltage dependent than time dependent. As explained above, the zener diodes Z 3 and Z 1 determine the turn-on and turn-off points of the sensing pulse. By making the circuit more responsive, capacitor C 10 tends to insure that the circuit will generate a sensing pulse almost immediately upon the firing of Z 3 . That is, the circuit will generate a sensing pulse based on the instantaneous value of the supply voltage, and not based on time since zero crossing.
[0056] Note that without C 10 , one would need too small a value for R 11 to generate pulses having a faster rise time. In general, the larger the resistance of R 11 , the more slowly the pulse reaches its full amplitude.
[0057] Also, capacitor C 10 operates in concert with capacitor C 5 and resistor R 11 to form a voltage divider network that provides performance superior to that obtained from the RC network of the previous CRC. More specifically, this RC network controls the slope of the leading edge of the sensing pulse. Without R 11 , the slope of the leading edge would be nearly vertical. The profile of the trailing edge of the pulse is determined partly by Z 1 , which controls the start of the turn-off, partly by the combination of R 13 and the gate capacitance of Q 1 , and partly by the response time of U 2 .
[0058] [0058]FIG. 9 shows another improvement, wherein the zener diode Z 3 is replaced by a silicon bilateral voltage triggered switch known as a SIDAC. The term SIDAC is a known term in the art, and is an acronym for “Silicon Diode for Alternating Current”. A SIDAC is similar to a thyristor, but does not have a gate. Instead, when the SIDAC reaches a “breakover” voltage, its internal resistance becomes very low, and the voltage drop across the device becomes very small. The SIDAC is more of a switch than a zener diode; after reaching breakover voltage, the SIDAC becomes essentially a short-circuit, with a constant, low resistance, and stays in this condition until its main terminal current is interrupted, or until the current drops below a holding value.
[0059] The SIDAC is especially useful in the CRC because it changes state very quickly, and produces very fast turn-on of switch Q 1 . The SIDAC thus helps to minimize switching losses in Q 1 , and thus reduces unwanted generation of heat. When a SIDAC is used, and when capacitor C 10 is installed across R 15 , as shown in FIG. 9, the performance of the circuit approaches that obtained from the quad comparator pulser circuit of FIG. 5, but with fewer components.
[0060] The improved CRC can shorten the duration of the sensing pulse, making it practical to use sensing pulses as short as about 100 microseconds. This feature results from the fact that the circuit is sufficiently responsive to make the leading and trailing edges of the sensing pulses essentially vertical.
[0061] All of the versions of the CRC of the present invention provide excellent compensation for variations in supply voltage. This feature is illustrated by the graph of FIG. 11, and by the waveform diagrams of FIGS. 12 - 15 , discussed below.
[0062] If one desires to have a sensing pulse of a desired amplitude, it is necessary that the sensing pulse be generated according to the instantaneous value of the supply voltage, and not according to time. That is, if the sensing pulse were always made to start, say, two milliseconds after the zero crossing point, the amplitude of the sensing pulse would change with variations in the supply voltage. To maintain the amplitude of the sensing pulses, it is necessary to make such pulses voltage-dependent rather than time-dependent.
[0063] The CRC of the present invention accomplishes the above object. In essence, the delay angle, i.e. the time following the zero crossing point before which the sensing pulse begins, is varied so as to maintain pulses of essentially constant amplitude. The change in delay angle is determined inherently by the set points of the zener diodes and/or the SIDAC. If the zener diode Z 3 , or the SIDAC, is set to conduct at a particular voltage, the sensing pulse will not be generated until that voltage is reached. Thus, the onset of the sensing pulse is determined by the firing voltage of the zener diode (or the breakover voltage of the SIDAC), and not by any pre-set time interval.
[0064] [0064]FIG. 11 shows how the delay angle must change, for various values of supply voltage, measured as a percentage of nominal design voltage. FIGS. 12 - 15 provide waveforms illustrating the cases represented in FIG. 11. In each of FIGS. 12 - 15 , the delay angle, i.e. the start of the sensing pulse, is somewhat different, but the amplitude of the sensing pulse is essentially the same. Experimental tests have shown that the amplitude of the sensing pulse may vary by less than 2% even when the supply voltage decreases by as much as 30%.
[0065] The exact shape and location of the sensing pulses depends on several interrelated considerations. In general, as explained above, it is usually desirable to shorten the width or duration of the pulse, in order to reduce power dissipation. But it is also necessary that the sensing pulse have sufficient amplitude to do the job it was intended to do. Therefore, it is not practical to provide a narrow pulse which starts at or near the zero crossing point, simply because the amplitude of the pulse would be insufficient.
[0066] The positioning of the sensing pulse depends on the following three criteria. First, from the standpoint of providing sensing current, one wants the sensing pulse to start relatively late in the waveform, so that its amplitude will be as large as possible. The maximum amplitude would occur if the delay angle were 90 degrees.
[0067] Secondly, in order to insure that the amplitude of the pulses will remain relatively independent of the supply voltage, it is necessary that the pulse amplitude be less than the maximum amplitude of the supply voltage. The maximum supply voltage is a limiting voltage; the amplitude of the sensing pulses cannot be any greater. Thus, if the delay angle were as great as 90 degrees, any reduction in the supply voltage would necessarily cause a reduction in the amplitude of the sensing pulses. But if the delay angle is less than 90 degrees, the amplitude of the sensing pulses may still be kept constant despite a decrease in supply voltage, as long as that amplitude is less than or equal to the minimum peak supply voltage. Thus, this consideration makes it undesirable to make the delay angle as great as 90 degrees.
[0068] Thirdly, starting the sensing pulse later in the waveform limits the energy available to deliver to the heating element. This consideration also dictates that the pulse be started earlier in the waveform.
[0069] In designing the circuit for use with a particular application, it is preferred first to choose a turn-off point for the pulse, and then design the turn-on point such that the width of the pulse will be about 150 microseconds, for example, or whatever the desired width will be. Stated another way, one selects the position of the turn-off point, and one starts the pulse as close as possible to that point. For a given nominal line voltage, a turn-off point of about 60 degrees provides a good compromise relative to considerations discussed above.
[0070] An additional reason for beginning the sensing pulse substantially after the zero crossing point is to reduce the effect of circuit transients. Inductance in the circuit may cause circuit disturbances at the moment of zero crossing, and such effects can degrade the quality of the sensing pulse, making the circuit less stable and less accurate. Starting the sensing pulse far away from the zero crossing point avoids this problem.
[0071] On the other hand, to the extent that wider pulses are desired, for the reasons described elsewhere in this specification, such as when higher PTC materials are used, one can use the same circuit topology to create wider pulses, simply by using components having different values. Wider pulses may be desirable where it is necessary to allow time for circuit transients to settle down.
[0072] The circuits of the present invention are sufficiently versatile to produce either wide or narrow pulses. By appropriate adjustment of component values, the sensing pulses may be as wide as about 4 milliseconds, or as narrow as about 100 microseconds.
[0073] Therefore, one of the novel features of the present invention is that it permits the user to choose the starting point of the sensing pulses.
[0074] Depending on the needs of the application, the starting point could be anywhere from near the zero crossing point (in which case the pulse might need to be wider than the case in which the pulse begins later, to provide sufficient sensing current), or it could be far away from the zero crossing point, or anywhere in between. In U.S. Pat. No. 6,100,510, by contrast, there is no such flexibility; in the prior circuit, the pulses of necessity begin shortly after the zero crossing point. Thus, in one aspect, the present invention comprises the method which includes choosing a starting point of the sensing pulse, the starting point being selected from a range which extends from the zero crossing point to the maximum point on the waveform.
[0075] The improved CRC of the present invention shows that sensing pulses of very short duration are practical, when using the circuit described in U.S. Pat. No. 6,100,510. Experimental tests have shown that pulse widths as short as 150 microseconds are feasible. The principal limiting factors on pulse width appear to be system electrical inductance, and the speed of response of the circuitry. The use of such narrow pulses substantially reduces circuit dissipation, and well below the levels experienced with circuitry built only according to the teachings of the cited patent. Short sensing periods permit the use of high peak sensing current. This capability allows the circuit to be used with very low PTC heating elements.
[0076] On the other hand, in certain cases, ultra-fast switching of sensing currents may not always be necessary or desirable. Ultra-fast switching of high sensing currents can cause power line disturbances that may affect other electrical equipment in the same facility. The potential problems associated with pulses having short rise times are exacerbated as the system inductance increases. Although necessary for some applications, such as low PTC heaters, fast switched, narrow pulses should only be used when needed.
[0077] Examples of applications that do not require ultra-fast switching almost always include heaters made from medium and high PTC element materials. In these applications, longer sensing pulse duration, and pulses having leading and trailing edges that are not nearly vertical, result in better tolerance for poor power supply conditions and for high inductance in the load circuit.
[0078] Therefore, the present invention makes it easier to tailor the CRC to the specific application. The present invention can be used to generate extremely narrow sensing pulses, or it can be adjusted to make the pulses less narrow.
[0079] As noted above, the tolerance of the present invention for variations in supply voltage is excellent. The circuit of the present invention automatically corrects for such variations, and the correction occurs within one or two cycles. This feature is of particular benefit when the circuit operates a very fast-response heater under typical manufacturing plant conditions. Motor starting loads, for example, often cause instantaneous swings of 10-15% in supply voltage. The fast compensation offered by the present invention improves the stability of the process being controlled.
[0080] Although somewhat more complex than the other embodiments, the quad comparator alternative has the advantage that it is more versatile and easier to configure for specific pulse characteristics. It provides the added capability to do either 16.6 millisecond or 8.3 millisecond sampling rates. Sampling rates of 8.3 milliseconds are useful mostly for heating systems having extremely low thermal inertia, and which have practically no inductance and very short time constants.
[0081] The invention can be modified in various ways, as will be apparent to the reader skilled in the art. For example, the electrical behavior of any device or network used at the position of Z 3 has a major effect on the performance of the circuit, and devices other than zener diodes and SIDACs, such as SCRs or the like, may be substituted in place of either of these components. The invention is not limited to analog components, but could be implemented by digital means, or by digitally-assisted means. Also, the invention need not generate pulses only at the beginning of positive half-cycles. By appropriate changes of components, one could modify the circuit to generate sensing pulses within negative half-cycles. These and other similar modifications should be deemed within the spirit and scope of the following claims.
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A heating unit includes a bridge having an arm in which there is located a heating element, and a circuit for directing a sensing current through the heating element. The circuit of the present invention reduces the duty cycle of the sensing current, thus reducing the average sensing current and allowing the use of higher peak sensing currents. In one embodiment, a set of zener diodes determines the start and stop points of the sensing current pulses. In another embodiment, the start and stop points are determined by electronic logic performed by a quad comparator. In another embodiment, one of the zener diodes is replaced by a SIDAC. The invention allows sensing of heating elements having very small temperature coefficients. The circuits of the invention produce a sensing current which is relatively unaffected by variations in supply voltage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/235,826, (now U.S. Pat. No. 7,604,106) filed on Sep. 23, 2008, entitled “Clutch System,” which is a continuation of U.S. application Ser. No. 11/289,010, filed on Nov. 29, 2005, entitled “Clutch System,” which is a continuation-in-part of U.S. application Ser. No. 10/970,356 (now U.S. Pat. No. 7,104,382) filed on Oct. 21, 2004, entitled “Clutch System,” the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
This document relates to a rotational control apparatus, and certain embodiments relate more particularly to a clutch apparatus.
BACKGROUND
Vehicle transmission systems, cooling systems, and braking systems often use clutches or like devices to selectively transmit rotational forces from a drive shaft to an output member. Conventional clutch devices include an opposing pair of engagement surfaces that can be compelled toward or away from one another using an electrical, mechanical, pneumatic, or hydraulic actuation system. In general, the actuation system causes some relative axial shifting within the clutch device. Such axial movement is used engage (or disengage) the opposing engagement surfaces, which rotationally interconnects (or rotationally disconnects) the drive shaft and the output member.
In clutch devices using pneumatic or hydraulic actuated systems, a piston may be acted upon by a set of springs to bias the piston toward one of the engaged or disengaged positions. Fluid pressure may act upon the piston, in a direction opposite to that of the spring force, to cause the piston portion to be axially shifted. Such axial movement is used engage (or disengage) the opposing engagement surfaces, thus selectively controlling the rotation between the drive shaft and the output member.
Clutch devices may require repair or replacement if the engagement surfaces have worn beyond their useful life or if a component is not properly functioning. For instance, seals and clutch engagement surfaces may wear over time and require replacement.
The design of the clutch device can have a significant effect on the time and cost of repair or replacement of component parts. If a clutch device has multiple pieces that must be disassembled before the clutch device can be removed from the drive shaft, the labor costs associated with the repair or replacement of the clutch device may increase. In addition, if a clutch device includes components that are spring biased, extra tooling may be required to clamp those components in place as clutch device is disassembled or removed.
The location and number of seals such as O-rings in the clutch device may also affect the time and cost associated with repairing or replacing clutch devices. If a seal fails and starts to leak, the time required to locate which particular seal is broken may increase if the clutch device has a larger number of seals. Furthermore, the location of the seals may affect the likelihood of contaminants entering the fluid space. If a seal is disposed between two surfaces that move both axially and rotationally relative to one another, the seal may be more susceptible to leakage.
The longevity of the clutch device, and thus the repair interval, may be increased by reducing wear factors such as vibration. Clutch designs built with more liberal tolerances and clutch designs that allow greater degrees of inter-part vibration may have a shorter useful life.
SUMMARY
A clutch system may include in certain embodiments a clutch body attached to a drive member such as a drive pulley, wherein the clutch body may be removed from the drive member without disassembling the clutch body. In various embodiments, the clutch body may include two clutch plates which enclose a spring-loaded pneumatic reciprocating assembly that in operation causes the plates to selectively separate and engage one another. In certain embodiments, the clutch body may be readily attached to a associated drive pulley in a single step by installation of a single set of fasteners.
In some embodiments, a rotation control apparatus may include a clutch member removably mounted to a drive pulley. The clutch member may have a hub portion and a piston portion. The hub portion may be selectively movable in a rotational direction relative to the drive pulley and substantially stationary in an axial direction relative to the drive pulley. The piston portion may be selectively movable in the axial direction relative to the hub portion and substantially stationary in the rotational direction relative to the hub portion. The clutch member may be removable from the drive pulley while the hub portion remains assembled with the piston portion.
In another embodiment, a rotational control apparatus includes a drive member rotatably mounted on a support shaft. The drive member may have a first engagement surface. A clutch member may be removably mounted to the drive member. The clutch member may comprise a piston portion assembled with a hub portion. The piston portion may be selectively movable in an axial direction relative to the hub portion and substantially stationary in a rotational direction relative. The piston portion may have a second engagement surface to selectively contact the first engagement surface. The clutch member may further include a channel in fluid communication with the piston portion, and a biasing member to urge the second engagement surface against the first engagement surface. The clutch member may be removable from the drive member while the hub portion remains assembled with the piston portion.
In some embodiments, a clutch member may include an engagement surface that at least partially extends in a nonradial direction. For example, the clutch member may include a frusto-conical engagement surface to selectively interface with clutch material. Particular embodiments may include a clutch device for removably mounting to a drive member. The clutch device may include a frusto-conical clutch ring, which may have an increasingly larger radius as the engagement surface extends away the driver member when the clutch device is mounted to the drive member.
These and other embodiments may be configured to provide one or more of the following advantages. First, the clutch member may be readily removed from the drive member upon removal of a single set of fasteners. Second, the clutch member may have a self-contained configuration that eliminates the need for additional clamps or tooling when removing the clutch member from the drive member. Third, the clutch member may have a reduced number of seals and leakage paths, thus reducing the number of seals along the periphery of the fluid-receiving chamber. Fourth, the seal member along the periphery of the fluid-receiving chamber may not rotate relative to an adjacent part, which may in turn improve seal quality and reduce the likelihood of contamination in the fluid system. Fifth, the clutch member may have a fluid-receiving chamber that is wholly within the removable clutch member, which may also reduce the likelihood of contamination in the fluid system. Sixth, a spline connection in the clutch member may reduce vibration between internal components of the clutch member. Seventh, the clutch member may use a single spring to urge the piston portion toward an engaged (or disengaged) position, which may simplify the assembly process during manufacture and repair. Some or all of these and other advantages may be provided by the clutch systems described herein.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is an exploded cross-sectional view of a rotational control apparatus in accordance with certain embodiments of the invention.
FIG. 2 is another exploded cross-sectional view of a rotational control apparatus of FIG. 1 .
FIG. 3 is a cross-sectional side view of the rotational control apparatus FIG. 1 .
FIG. 4 is another cross-sectional side view of the rotational control apparatus of FIG. 1 .
FIG. 5 is an exploded cross-sectional view of a rotational control apparatus in accordance with certain embodiments of the invention.
FIG. 6 is a cross-sectional side view of the rotational control apparatus FIG. 5 .
FIG. 7 is another cross-sectional side view of the rotational control apparatus of FIG. 5 .
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
A number of embodiments of the invention include a rotational control apparatus that provides simplified repair or replacement. A rotation control apparatus may include a clutch member that is removably mounted to a drive member. In some embodiments, the clutch member may be removed from the drive member without disassembly of the clutch member's component parts.
Referring to FIGS. 1-2 , a drive member 100 is rotatably coupled to a support member 115 by one or more bearings 120 . A nut or collar device 116 is secured to the support member 115 and is abutted to the bearing 120 so that the bearings 120 remain substantially fixed in the axial direction relative to the support member 115 . The drive member 100 receives one or more drive inputs, such as belts, chains, gears or the like, to force the drive member 100 to rotate in a particular direction about an axis 105 . In this embodiment, the support member 115 is a substantially stationary shaft, and the drive member 100 is illustrated as a drive pulley that includes an input portion 102 . Rotational power from a motor or the like may be transmitted through one or more drive inputs (not shown in FIGS. 1-2 ) to the input portion 102 , thus causing the drive pulley 100 to rotate about the central axis 105 of the support shaft 115 .
A fluid supply input 150 extends into the support member 115 for connection to a fluid supply reservoir (not shown in FIGS. 1-2 ). A supply channel 152 extends from the fluid supply input 150 in a substantially axial direction along the central axis 105 . In this embodiment, the supply channel 152 extends through a cylindrical outlet 160 , which has a mating end 162 to mate with a face seal 260 of the clutch member 200 . The outlet 160 may also include a spacer 164 that fits into a shoulder 117 of the support member 115 , thereby aligning the outlet 160 with the central axis 105 .
Still referring to FIGS. 1-2 , the outlet 160 has an insert end 161 that is fit into a biasing member 163 . The biasing member 163 of the outlet 160 is fit into an axial cavity 161 of the support member 115 . The biasing member 163 may be a spring or block of elastic material that biases the mating end 162 in a substantially axial direction toward the face seal 260 . As such, when the clutch member 200 is mounted to the drive member 100 (see, for example, FIG. 3 ), the mating end 162 is pressed against the face seal 260 to form a mechanical seal. Accordingly, the fluid may be transmitted from the fluid supply input 150 through the outlet 160 and the face seal 260 to the fluid-receiving chamber 264 of the clutch member 200 . In some embodiments, the mating end 162 , the face seal 260 , or both may comprise metals, polymers, or composite materials that can substantially maintain the mechanical seal therebetween while the clutch member 200 is selectively rotated relative to the support member 115 . In one example, the mating end 162 and the face seal 260 comprise a hardened, polished steel material. This configuration of the mechanical seal between the mating end 162 and the face seal 260 may eliminate the need for a cap member that is fit over the mating end 162 and extends to the inner circumference of the drive pulley 100 so as to seal the radial area inside the drive pulley 100 and retain a face seal 260 .
The fluid transmitted to the fluid-receiving chamber 264 of the clutch member 200 may be any suitable liquid or gas, as described in more detail below. Such fluids may be received, for example, from a pneumatic air supply system or a hydraulic oil supply system.
Referring more closely to FIG. 1 , the clutch member 200 is removably mounted to the drive pulley 100 . A fluid channel 262 extending axially through the face seal 260 is substantially axially aligned with the central axis 105 . In this embodiment, the clutch member 200 is removably mounted to the drive pulley 100 using bolts 110 that screw into threaded cavities 112 in the drive pulley 100 . Alternatively, clamps may be used to removably couple the clutch member 200 to the drive member 100 .
Such a configuration of the clutch member 200 may permit the clutch member 200 to be readily removed from the drive pulley 100 . The clutch member 200 may be removed and/or replaced in a single operation by removing a single set of bolts 110 . This configuration may obviate the need to disassemble parts of the clutch member 200 during a replacement or repair operation. Moreover, the clutch member 200 in certain configurations may lessens or eliminates the need for additional clamps or tooling when removing the clutch member 200 from the drive member 100 , as described in more detail below. Accordingly, the time and costs associated with the repair or replacement of the clutch member 200 may be significantly reduced.
Referring again to FIGS. 1-2 , the clutch member 200 includes a piston portion 220 that is movably assembled with a hub portion 240 . The piston portion 220 is movable in an axial direction relative to the hub portion 240 and is substantially stationary in a rotation direction relative to the hub portion 240 . In this embodiment, the motion of the piston portion 220 relative to the hub portion 240 is accomplished by way of a spline connection. The piston portion 220 includes a first spline member 224 that is substantially mated with a second spline member 244 of the hub portion 240 . The splines 229 of the first spline member 224 are complimentary to the splines 246 of the second spline member 244 such that the spline members 224 and 244 are slidable relative to one another in an axial direction and are substantially stationary relative to one another in a rotational direction. In other embodiments, the motion of the piston portion 220 relative to the hub portion 240 may be accomplished using one or more bushings that permit relative axial movement and anti-rotation dowels that substantially prevent relative rotation between the piston portion 220 and the hub 240 .
In the embodiment depicted in FIGS. 1-2 , the piston portion 220 includes an output member 222 , the first spline member 224 , and a spring-engaging member 226 . The spring-engaging member 226 has a radially extending surface 227 that abuts with a spring 280 . The spring-engaging member 226 is fixedly coupled to the output member 222 , for example, by bolts 228 screwed into threaded cavities 223 in the output member 222 . The first spline member 224 is fixedly coupled to an output member 222 , for example, by threads on an external surface 225 of the first spline member 224 that are mated into a threaded cavity 221 of the output member 222 . Alternatively, the first spline member 224 may be fixedly coupled to an output member 222 , for example, by bolts screwed into threaded cavities in the output member 222 . The output member 222 includes studs 230 that are configured to receive an output device, such as fan blades (not shown in FIGS. 1-2 ). Accordingly, the clutch member 200 may engage the drive pulley 100 so that the output member 222 rotates with the drive pulley 200 to spin the fan blades. In such embodiments, the piston portion 220 of the clutch member 200 may have a dual function to selectively engage the drive pulley 100 and to act as the output for the rotational motion. The studs 230 may be mounted into cavities 231 in the output member 222 . In the presently preferred embodiment, the cavities 231 do not extend completely through the output member 222 , thereby obviating the need for additional seals between the studs 230 and the fluid-receiving chamber 264 . In other embodiments, the studs 230 may be threaded bolts that are inserted through threaded apertures in the output member 222 and extend forward of the output member 222 .
Still referring to FIGS. 1-2 , the hub portion 240 includes a hub 242 and the second spline member 244 . The second spline member 244 is fixedly coupled to the hub 242 , for example, by threads on an external surface 245 of the second spline member 244 that are mated into a threaded cavity 243 of the hub 242 . Alternatively, the second spline member 244 may be fixedly coupled to the hub 242 , for example, by bolts screwed into threaded cavities in the hub 242 . The hub 242 includes a cavity 248 configured to receive at least a portion of the face seal 260 , and the fluid channel 262 extends axially along the central axis 105 through both the hub 242 and the second spline member 244 . The face seal 260 may include threads on an external surface 261 that mate with the cavity 248 of the hub 242 . In an alternative embodiment, the threaded cavity 243 may extend completely through the hub 242 such that the second spline member 244 mates with the face seal 260 . In such an embodiment, the face seal 260 may mate with a cavity in the second spline member 244 similar to the cavity 248 in the hub 242 .
At least one bearing 270 is disposed between the hub 242 and a fixed plate 275 . The fixed plate 275 is mounted to the drive pulley 100 using the bolts 110 that are positioned through apertures 276 and screwed into cavities 112 . As such, the fixed plate 275 is secured to the drive pulley 100 and rotates along with the drive pulley. The bearing 270 permits the hub portion 240 (including the hub 242 ) to rotate independently of the fixed plate 275 and the drive pulley 100 . In this embodiment, the bearing 270 is disposed along an outer circumferential surface 241 of the hub 242 . The bearing 270 may be secured to the hub 242 and the fixed plate 275 using any number of securing means, such as collar devices, locking nuts, locking rings, tongue and groove arrangements, or the like. In this embodiment, the bearing 270 is secured to the hub 242 using a locking nut 271 so that the bearing 270 remains substantially stationary relative to the hub 242 in the axial direction. The bearing 270 is secured to the fixed plate 275 using a locking ring 271 such that the bearing 270 remains substantially stationary relative to the fixed plate 275 in the axial direction. As such, the hub portion 240 may rotate independently of the fixed plate 275 and drive pulley 100 , but the hub portion 240 remains substantially stationary in the axial direction relative to the fixed plate 275 and drive pulley 100 .
Still referring to FIGS. 1-2 , the hub 242 includes a spring-engaging surface 247 that abuts with the spring 280 . In this embodiment, the spring 280 is a single, coiled spring that has an inner and outer diameter to fit securely within the spring-engaging member 226 of the piston portion 220 . Using only a single spring may simplify assembly and disassembly of the clutch member 200 during manufacture or repair. Because only one spring must be placed in the spring-engaging member 226 , less time is required to properly align the spring 280 during assembly. Alternatively, other embodiments may use a more complex arrangement having a greater number of smaller springs that are positioned adjacent one another within the spring-engaging member 226 of the piston portion 220 .
When the clutch member 200 is assembled as shown in FIG. 1 , the spring 280 is compressed between the spring-engaging surface 227 of the piston portion 220 and the spring engaging surface 247 of the hub portion 240 . Such an arrangement urges the piston portion 220 in an axial direction toward the drive pulley 100 . Thus, in this embodiment, the spring 280 biases the piston portion 220 such that an engagement surface 237 of the piston portion 220 is urged against a clutch material 277 , which is mounted to the drive pulley 100 using the bolts 110 . When the engagement surface 237 presses against the clutch material 277 , the clutch member 200 engages the drive pulley 100 , and the piston portion 220 and the hub portion 240 rotate with the drive pulley 100 .
Still referring to FIGS. 1-2 , the clutch member 200 may disengage the drive pulley 100 when fluid is introduced into the chamber 264 under sufficient pressure to axially shift the piston portion 220 relative to the hub portion 240 . When the engagement surface 237 is shifted away from the clutch material 277 (see, for example, FIG. 4 ), the piston portion 220 and the hub portion 240 are no longer driven by the rotation of the drive pulley 100 and are free to independently rotate (or stop rotating) via the bearing connection 270 . As previously described, fluid may enter the chamber 264 through the fluid channel 262 . In this embodiment, the fluid-receiving chamber 264 is at least partially defined by the space between the output member 222 and the hub 242 . The fluid may pass through small gaps in the spline connection between the first spline member 224 and the second spline member 244 . When a predetermined amount of fluid pressure has built up in the chamber 264 , the output member 222 is forced in an axial forward direction away from the drive pulley 100 , thus overcoming the bias of the spring 280 to urge the piston portion 220 toward the drive pulley 100 .
Still referring to FIGS. 1-2 , the fluid-receiving chamber 264 is disposed internally in the clutch member 200 . In this embodiment, the fluid in the chamber 264 may have only one possible leak path, which is along the circumferential surface 249 of the hub 242 . A seal 290 is disposed along the periphery of the leak path between the circumferential surface 249 of the hub 242 and the output member 222 . The seal 290 is positioned as such to prevent fluid leakage through the leak path. Thus, a fluid leak may be quickly detected and repaired by checking the seal 290 at the circumferential surface 249 and by checking the mechanical seal at the face seal 260 . By reducing the number of seals in the clutch member design, the time and cost associated with detecting which seal is faulty may be significantly reduced.
In this embodiment, the seal 290 for the fluid-receiving chamber 264 is internal to the clutch member 200 and is disposed between two surfaces that do not rotate relative to one another about the central axis 105 . As previously described, the piston portion 220 may shift in the axial direction relative to the hub portion 240 , so the seal may endure a sliding motion between the circumferential surface 249 and the output member 222 . The piston portion 220 remains substantially stationary relative to the hub portion 240 in the rotational direction, so the seal 290 does not endure a rotational motion. When the seal 290 is internal to the clutch member 200 and is limited to such minimal sliding motion, the possibility of contaminants entering the chamber 264 through the seal 290 may be significantly reduced. Such a reduction is contamination may increase the longevity the clutch member 200 and may reduce the need for repair or replacement.
Referring to FIGS. 1-2 , a wiper seal 291 may also be disposed between the circumferential surface 249 of the hub portion 240 and the output member 222 of the piston portion 220 . In this embodiment, the wiper 291 may slide in an axial direction when the piston portion 220 shifts relative to the hub portion 240 . The wiper 291 is positioned against the circumferential surface 249 so as to prevent or limit any contaminants that may pass into the fluid-receiving chamber. The wiper 291 , the seal 290 , or both may comprise a material that is suitable to endure the sliding motion while limiting the flow of fluid or contaminants. Such suitable materials may include polymers, rubber materials, composite materials, or the like. Depending on the manufacturing tolerances of the piston portion 220 and the hub portion 240 , a guide band (not shown in FIGS. 1-2 ) may be disposed between the circumferential surface 249 and the output member 222 to prevent excess metal-on-metal contact between the circumferential surface 249 and the output member 222 . If such a guide band is implemented, the guide band is preferably disposed between the seal 290 and the wiper 291 .
Referring more specifically now to FIG. 1 , the clutch member 200 may have a self-contained construction such that the components of clutch member 200 (e.g., the piston portion 220 , the hub portion 240 , the spring 280 , and so forth) remain in an assembled state even after the clutch member is removed from the drive pulley 100 . In the embodiment shown in FIG. 1 , the clutch member 200 may be removed from the drive pulley 100 by removing the bolts 110 from the mounting cavities 112 . Removing these bolts 110 , however, does not permit the internal spring to move the components of the clutch member 200 apart from another and thereby cause disassembly of the clutch member 200 (e.g., the spring 280 is not be free to unexpectedly expand and separate the components when a worker attempts to remove the clutch member 200 from the drive pulley 100 ). The locking nut 272 , locking ring 271 , and other such devices may be subsequently removed to disassemble the clutch member 200 at the appropriate time. Accordingly, the clutch member 200 may be removed from the drive pulley 100 without the use of clamps or extra tooling to retain the clutch member 200 in its assembled position.
In operation, the clutch member 200 may selectively engage the drive member 100 so that the rotation of the output member 222 is controlled. As previously described, the depicted embodiment of the clutch member 200 may disengage the drive pulley 100 when fluid is introduced into the chamber 264 under sufficient pressure to axially shift the piston portion 220 relative to the hub portion 240 . When the engagement surface 237 is shifted away from the clutch material 277 , the piston portion 220 and the hub portion 240 are no longer driven by the rotation of the drive pulley 100 and are free to independently rotate (or stop rotating) via the bearing connection 270 .
Referring now to FIG. 3 , the clutch member 200 is mounted to the drive pulley 100 and the piston portion 220 is shown in an engaged position. In this embodiment, the spring 280 is disposed between the hub portion 240 and the piston portion 220 such that the spring 280 urges the piston portion 220 in a rearward axial direction toward the drive pulley 100 . The engagement surface 237 of the piston portion 220 is pressed against the clutch material 277 , which is mounted to the drive pulley 100 . The engagement surface 237 is urged against the clutch material 277 with sufficient force so that the piston portion 220 rotates along with the clutch material 277 , which is mounted to the drive pulley 100 . As such, the output member 222 of the piston portion 220 rotates substantially synchronously with the rotation of the drive pulley 100 about the central axis 105 . When the piston portion 220 is in the engaged position, the output device (such as a fan) that is mounted to the studs 230 of the output member 222 also rotates with the drive pulley 100 . Although the hub portion 240 is not directly engaged with the drive pulley 100 or the clutch material 277 , the hub portion 240 rotates with the piston portion 220 due to the spline connection between first and second spline members 224 and 244 . Such a configuration limits the wear on the seal 290 because the seal 290 does not endure rotational motion between the hub 242 and the output member 222 .
Referring now to FIG. 4 , the piston portion 220 is shifted forward in the axial direction away from the drive pulley 100 such that the piston is in a disengaged position. In this embodiment, the engagement surface 237 of the piston portion 220 is spaced from the clutch material 277 by an offset 300 . This offset 300 causes the piston portion 220 to disengage with the clutch material 277 so that the rotational motion from the drive pulley 100 is not transferred to the output member 222 . When the piston portion 220 is in the disengaged position, the piston portion 220 and hub portion 240 are free to rotate independently from the drive pulley 100 due to the bearing connection 270 . Accordingly, the piston portion 220 and the hub portion 240 may stop rotating even though the drive pulley 100 continues to rotate.
Referring to FIGS. 3-4 , the offset 300 of the piston portion 220 occurs when a fluid under sufficient pressure is received in the chamber 264 . If force from the fluid pressure in the chamber 264 is sufficient to overcome the force of the spring 280 , the output member 222 (and the entire piston portion 220 ) is shifted forward in the axial direction. In some embodiments, the fluid pressure that is required to overcome the spring force may be approximately predetermined from the spring constant, the desired offset 300 , the dimensions of the chamber 264 , and other such factors. As previously described, the fluid supply input 150 receives the fluid from the reservoir (not shown in FIGS. 3-4 ). The fluid passes through the fluid supply channel 152 , through the outlet 160 and the face seal 260 , through the fluid channel 262 , and into the chamber 264 . The mechanical seal at the face seal 260 assures that the fluid properly reaches the chamber 264 , and when the fluid is in the chamber 264 , the seal 290 prevents the fluid from passing through the potential leak path along the circumferential surface 249 ( FIG. 2 ).
In this embodiment of the clutch member 200 depicted in FIGS. 3-4 , the piston portion 220 serves as both the portion that engages the drive pulley 100 (via the clutch material 277 ) and the portion that receives an output device (such as a fan). The output device mounted to the studs 230 of the piston portion 220 may also be shifted in the axial direction as the piston portion 220 is shifted, but the offset 300 in the axial direction may be relatively small such that this shifting motion has little or no impact on the output device. Similarly, the offset 300 in the axial direction may be relatively small such that the shifting motion of the output member 222 relative to the hub 242 has little or no impact on the longevity and performance of the seal 290 and the wiper 291 . It should be understood that the displacement between the clutch material 277 and the engagement surface 237 may change slightly as the clutch material 277 is worn away through normal use.
In another embodiment of the invention, the drive member 100 may have a configuration other than a drive pulley shown in FIGS. 1-4 . For example, the drive member 100 may be a shaft or gear that is powered by a motor. In such embodiments, the clutch member 200 may have a mounting configuration to removably attach to the shaft or gear or may have an adapter member connected therebetween.
In other embodiments, the output member 222 of the clutch member 200 may be configured to receive an output device other than fan blades. For example, the output member 222 may be configured to connect with other components that are to be selectively rotated, such as output shafts, gears, brake systems, and the like.
In yet another embodiment, the spring 280 that biases the piston portion 220 in an axial direction is not limited to a single, coiled spring shown in FIGS. 1-4 . Rather, the spring 280 can be any biasing member that can urge the piston portion 220 in the axial direction. A suitable biasing member may comprise one or more coil springs, leaf springs, gas springs, solid materials having appropriate elasticity properties, or the like.
Furthermore, some embodiments of the invention may include a clutch member configuration such that spring 280 urges the piston portion 220 to disengaged position (where the engagement surface 237 is offset from the clutch material 277 ). In such embodiments, the chamber 264 may be configured such that fluid pressure therein causes the piston portion 220 to shift toward engaged position (where the engagement surface 237 is pressed against the clutch material 277 ).
In other embodiments, the clutch material 277 may be integral with the fixed plate 275 or the drive member 100 . In these embodiments, the engagement surface 237 of the piston portion 220 would engage with an opposing surface on the fixed plate 275 of the drive member 100 .
In another embodiment, the clutch material may be mounted to the piston portion 220 such that the clutch material selectively engages with an opposing surface (e.g., the clutch material 277 , the fixed plate 275 or the drive member 100 ). In such an embodiment, an engagement surface on the clutch material would contact the opposing surface.
Referring to FIGS. 5-7 , some embodiments of a clutch member 600 may include an engagement surface 637 that at least partially extends in a nonradial direction. For example, a clutch member 600 may include a frusto-conical interface between the clutch material and the engagement surface. In this embodiment, a frusto-conical clutch ring 677 may selectively engage a frusto-conical surface 637 . The frusto-conical engagement surface 637 has a first radius 639 and a second radius 641 , with the first radius 639 being axially closer to drive member 500 . In this embodiment, the first radius 639 is smaller than the second radius 641 . As such, the frusto-conical clutch ring 677 may have an increasingly larger radius as the engagement surface extends away from the drive member 500 when the clutch member 600 is mounted to the drive member 500 .
Similar to some previously described embodiments, the drive member 500 can be rotatably coupled to a support member 515 by one or more bearings 520 . The drive member 500 receives one or more drive inputs, such as belts, chains, gears or the like, to force the drive member 500 to rotate in a particular direction about an axis 505 . In this embodiment, the support member 515 is a substantially stationary shaft, and the drive member 500 is illustrated as a drive pulley that includes an input portion 502 .
A fluid supply input 550 extends into the support member 515 for connection to a fluid supply reservoir (not shown in FIGS. 5-7 ). A supply channel 552 may extend from the fluid supply input 550 in a substantially axial direction along the central axis 505 . In this embodiment, the supply channel 552 mates with a face seal 660 of the clutch member 600 . When the clutch member 600 is mounted to the drive member 500 (see, for example, FIG. 6 ), the supply channel 552 is pressed against the face seal 660 to form a mechanical seal. Accordingly, the fluid may be transmitted from the fluid supply input 550 , through a fluid channel 662 , and to the fluid-receiving chamber 664 of the clutch member 600 .
Referring to FIG. 5 , the clutch member 600 may be removably mounted to the drive member 500 . In this embodiment, the clutch member 600 is removably mounted to the drive member 500 using bolts 510 that screw into threaded cavities 512 in the drive member 500 . In another embodiment, clamps may be used to removably couple the clutch member 600 to the drive member 500 .
Such a configuration of the clutch member 600 may permit the clutch member 600 to be readily removed from the drive member 500 . The clutch member 600 may be removed and/or replaced in a single operation by removing a single set of bolts 510 . Similar to some previously described embodiments, this configuration may obviate the need to disassemble parts of the clutch member 600 during a replacement or repair operation.
Still referring to FIG. 5 , the clutch member 600 includes a piston portion 620 that is movably assembled with a hub portion 640 . The piston portion 620 is movable in an axial direction relative to the hub portion 640 and is substantially stationary in a rotation direction relative to the hub portion 640 . Similar to some previously described embodiments, the motion of the piston portion 620 relative to the hub portion 640 may be accomplished by way of a spline connection. The piston portion 620 includes a first spline member 624 that may be substantially mated with a second spline member 644 of the hub portion 640 .
The piston portion 620 includes studs 630 that are configured to receive an output device, such as fan blades (not shown in FIGS. 5-7 ). Accordingly, the clutch member 600 may engage the drive member 500 so that the piston portion 620 rotates with the drive member 500 to spin the fan blades. In such embodiments, the piston portion 620 of the clutch member 600 may have a dual function to selectively engage the drive member 500 and to act as the output for the rotational motion.
In this embodiment, the hub portion 640 includes a hub 642 and the second spline member 644 . The hub 642 includes a cavity 648 configured to receive at least a portion of the face seal 660 , and the fluid channel 662 extends axially along the central axis 505 through both the hub 642 and the second spline member 644 . Similar to some previously described embodiments, a seal 690 may be disposed along the periphery of the leak path between hub 642 and the output member 622 . The seal 690 is positioned as such to prevent fluid leakage through the leak path. Thus, a fluid leak may be quickly detected and repaired by checking the seal 690 at the circumferential surface and by checking the mechanical seal at the face seal 660 . By reducing the number of seals in the clutch member design, the time and cost associated with detecting which seal is faulty may be significantly reduced. Similar to some previously described embodiments, the clutch member 600 may optionally include a wiper seal 691 . The wiper seal 691 may prevent migration of contaminants toward the seal 690 that actually borders the fluid receiving chamber 664 .
At least one bearing 670 may be disposed between the hub 642 and a fixed plate 675 . The fixed plate 675 may be removably mounted to the drive member 500 using the bolts 510 that are positioned through apertures 676 and screwed into cavities 512 . As such, the fixed plate 675 can be secured to the drive member 500 and rotates along with the drive member 500 . The bearing 670 permits the hub 642 to rotate independently of the fixed plate 675 and independently of the drive member 500 . In this embodiment, the bearing 670 may be secured to the hub 642 using a locking nut 672 so that the bearing 670 remains substantially stationary relative to the hub 642 in the axial direction. The bearing 670 may be secured to the fixed plate 675 using a locking ring 671 such that the bearing 670 remains substantially stationary relative to the fixed plate 675 in the axial direction. As such, the hub 642 may rotate independently of the fixed plate 675 and independently of the drive member 500 , but the hub 642 remains substantially stationary in the axial direction relative to the fixed plate 675 and drive member 500 .
Still referring to FIG. 5 , the hub 642 includes a spring-engaging surface 647 that abuts with a biasing member, such as a spring 680 . In this embodiment, the spring 680 is a single, coiled spring that has an inner and outer diameter to fit securely within the spring-engaging member 626 of the piston portion 620 .
When the clutch member 600 is assembled as shown in FIG. 5 , the spring 680 may be compressed between the spring-engaging surface 627 of the piston portion 620 and the spring engaging surface 647 of the hub 642 . Such an arrangement urges the piston portion 620 in an axial direction toward the drive member 500 . Thus, in this embodiment, the spring 680 biases the piston portion 620 such that the frusto-conical clutch ring 677 (mounted to the piston portion 620 in this embodiment) is urged against the frusto-conical engagement surface 637 of the fixed plate 675 , which is mounted to the drive member 500 using the bolts 510 . When the frusto-conical clutch ring 677 of the piston portion 620 presses against the frusto-conical engagement surface 637 of the fixed plate 675 , the piston portion 620 engages the fixed plate 675 , and the piston portion 620 rotates with the drive member 500 . The clutch ring 677 may comprises a metallic, ceramic or other material that is capable of providing frictional engagement and is capable of dissipating heat generated at the frictional interface. For example, some embodiments of the clutch ring 677 may comprise a material having a static coefficient or friction in the range of approximately 0.2 to approximately 0.6 and, in particular embodiments, may comprises a material having a static coefficient of friction in the range of approximately 0.4 to approximately 0.5.
Still referring to FIG. 5 , the piston portion 620 may disengage the hub 642 when fluid is introduced into the chamber 664 under sufficient pressure to axially shift the piston portion 620 relative to the hub portion 640 . Such an axial shift of the piston portion 620 may cause the frusto-conical clutch ring 677 to disengage the opposing engagement surface (e.g., the engagement surface 637 of the fixed plate 675 in this embodiment). In such circumstances, the piston portion 620 may not be driven by the rotation of the drive member 500 so that the piston portion 620 is free to independently rotate (or stop rotating) due to the bearing connection 670 .
In this embodiment, the fluid-receiving chamber 664 is at least partially defined by the space between the output member 622 and the hub 642 . In some embodiments, the fluid may pass through small gaps in the spline connection between the first spline member 624 and the second spline member 644 . When a predetermined amount of fluid pressure has built up in the chamber 664 , the output member 622 is forced in an axial forward direction away from the hub 642 , thus overcoming the bias of the spring 680 to urge the piston portion 620 in the axial forward direction.
Similar to some previously described embodiments, the clutch member 600 may have a self-contained construction such that the components of clutch member 600 (e.g., the piston portion 620 , the hub portion 640 , the spring 680 , the frusto-conical clutch ring 677 , and so forth) remain in an assembled state even after the clutch member 600 is removed from the drive member 500 . In the embodiment shown in FIG. 5 , the clutch member 600 may be removed from the drive member 500 by removing the bolts 510 from the mounting cavities 512 .
Referring now to FIGS. 6-7 , the clutch member 600 may be operated to selectively engage the drive member 500 so that the rotation of the output member 622 is controlled. As previously described, the depicted embodiment of the clutch member 600 may disengage the drive member 500 when fluid is introduced into the chamber 664 under sufficient pressure to axially shift the piston portion 620 relative to the hub portion 640 . When the frusto-conical clutch ring 677 is shifted away from the frusto-conical engagement surface 637 , the piston portion 620 is no longer driven by the rotation of the drive member 500 (and the fixed plate 675 ) and is thereby free to independently rotate (or stop rotating) via the bearing connection 670 .
As shown in FIG. 6 , the clutch member 600 is mounted to the drive member 500 , and the piston portion 620 is in an engaged position. In this embodiment, the spring 680 is disposed between the hub portion 640 and the piston portion 620 such that the spring 680 urges the piston portion 620 in a rearward axial direction (toward the drive member 500 ). The frusto-conical clutch ring 677 of the piston portion 620 is pressed against the frusto-conical engagement surface 637 of the fixed plate 675 , which is mounted to the drive member 500 . The frusto-conical clutch ring 677 is urged against frusto-conical engagement surface 637 with sufficient force so that the piston portion 620 rotates along with the fixed plate 675 , which is mounted to the drive member 500 . As such, the output member 622 of the piston portion 620 rotates substantially synchronously with the rotation of the drive member 500 about the central axis 505 . When the piston portion 620 is in the engaged position, the output device (such as a fan or fan blades) that is mounted to the studs 630 of the output member 622 also rotates with the drive member 500 . Although the hub 642 is not directly engaged with the drive member 500 or the frusto-conical engagement surface 637 of the fixed plate 675 , the hub 642 rotates with the piston portion 620 due to the spline connection between the first and second spline members 624 and 644 . Such a configuration may limit the wear on the seal 690 because the seal 690 does not endure rotational motion between the hub 642 and the output member 622 .
Referring now to FIG. 7 , the piston portion 620 may be shifted forward in the axial direction away from the drive member 500 such that the piston portion 620 is in a disengaged position. In this embodiment, the frusto-conical clutch ring 677 may be mounted to the piston portion 620 so it is axially shifted away from the frusto-conical engagement surface 637 by an offset 700 . This offset 700 causes the piston portion 620 to disengage with the fixed plate 675 so that the rotational motion from the drive member 500 is not transferred to the output member 622 . When the piston portion 620 is in the disengaged position, the piston portion 620 and hub portion 640 are free to rotate independently from the drive member 500 due to the bearing connection 670 . Accordingly, the piston portion 620 and the hub 642 may stop rotating even though the drive member 500 and the fixed plate 675 continue to rotate. It should be understood that, in other embodiments, the clutch ring 677 may be mounted to the fixed plate 675 , in which case the clutch ring 677 may selectively engage a frusto-conical surface 628 of the piston portion 620 . In such circumstances, the piston portion 620 may be axially shifted to cause an offset between the clutch ring 677 and the frusto-conical surface 628 .
Referring to FIGS. 6-7 , the offset 700 of the piston portion 620 may occur when a fluid under sufficient pressure is received in the chamber 664 . If force from the fluid pressure in the chamber 664 is sufficient to overcome the force of the spring 680 , the output member 622 (and, in this embodiment, the entire piston portion 620 ) is shifted forward in the axial direction. In some embodiments, the fluid pressure that is required to overcome the spring force may be approximately predetermined from the spring constant, the desired offset 700 , the dimensions of the chamber 664 , and other such factors. As previously described, the fluid supply input 550 may receive the fluid, such as air, from the reservoir (not shown in FIGS. 6-7 ). The fluid passes through the fluid supply channel 552 , through the fluid channel 662 , and into the chamber 664 . The mechanical seal at the face seal 660 assures that the fluid properly reaches the chamber 664 , and when the fluid is in the chamber 664 , the seal 690 may prevent the fluid from passing through a potential leak path along the circumferential surface 649 of the hub 642 .
Some embodiments of a clutch member 600 having a frusto-conical engagement surface 637 , such as those embodiments described in connection with FIGS. 5-7 , may provide substantial torque transfer capabilities between the drive member 500 and the output device. For example, some embodiments of the clutch member 600 may provide torque ratings of approximately 2700 in-lbs, 2800 in-lbs, 2900 in-lbs, 3000 in-lbs, or more, and particular embodiments may provide torque ratings in the range of approximately 3000 in-lbs to approximately 5000 in-lbs. As described in more detail below, the coefficient of friction of the clutch ring 677 , the conical angle of the clutch ring 677 , the force of the spring 680 , and other factors affect the torque rating of the clutch member 600 .
These substantial torque transfer capabilities may be caused by a number of factors. For example, the shape and orientation of the frusto-conical engagement surface 637 and the frusto-conical clutch ring 677 may provide the clutch member 600 with a conical wedging action. This conical wedging action may improve the engagement friction, thereby providing an increase in the torque transfer capabilities.
In another example, the shape and orientation of the frusto-conical engagement surface 637 and the frusto-conical clutch ring 677 may provide the clutch member 600 with a reduced rotational moment of inertia. Because some embodiments of the frusto-conical clutch ring 677 do not necessarily extend as far in an outward radial direction, the piston portion 620 may have less radial mass (in the form of metallic portions or other components extending generally in an outward direction away from the rotational axis). As such, the overall rotational moment of inertia of the piston portion 620 may be reduced, which may increase the torque transfer capabilities of the clutch member 600 .
Torque capability testing may be conducted on clutch members 600 to determine the torque ratings. For example, a torque capability test method may include mounting the clutch member 600 to a drive member 500 , as shown, for example, in FIG. 6 . The torque capability testing method may also include securing the drive member 500 in a fixed position (e.g., in a vice or a similar device), which in turn secures the position of the engagement surface 637 (e.g., disposed on the fixed plate 675 in the depicted embodiments). In this example, a torque measuring device (e.g., a torque meter or the like) may be secured to the output member 622 . In accordance with this implementation of the torque capability test method, the clutch member may be in an engaged condition so that the frusto-conical clutch ring 677 is in frictional contact with the engagement surface 637 . The torque measuring device may be used to measure a torque applied to the output member 622 relative to the drive member 500 (e.g., applying a force in an attempt to rotate the output member 622 ) and may be monitored to determine the torque level required to cause slippage between the output member 622 and the drive member 500 . This implementation of the torque capability test method may be used to determine the torque rating of the clutch member 600 (e.g., the level of torque required to cause slippage between the output member 622 and the drive member 500 when the clutch member 600 was in an engaged condition).
Certain factors of the clutch member's configuration may affect the torque transfer capabilities and the torque rating of the clutch member 600 . For example, the conical angle of the clutch ring 677 (refer, for example, to angle A in FIG. 7 ) may be selected to optimize the torque rating of the clutch member 600 . In some embodiments, the conical angle A may be approximately 10 degrees to approximately 60 degrees, approximately 15 degrees to approximately 45 degrees, or approximately 20 to approximately 40 degrees. In the embodiment depicted in FIGS. 5-7 , the conical angle A is approximately 30 degrees.
In another example of a factor that can affect the torque transfer capabilities, the material of the clutch ring 677 and/or the engagement surface 637 may be selected to provide a particular coefficient of friction. In some embodiments, the clutch member 600 may include clutch ring material having a static coefficient of friction in the range of approximately 0.3 to approximately 0.6, approximately 0.35 to approximately 0.55, or approximately 0.4 to approximately 0.55. Suitable materials for the clutch ring 677 may be provided, for example, by Trimat Ltd. of Brierley Hill, England or by Scan Pac Mfg., Inc. of Menomonee Falls, Wis.
In a further example of a factor that can affect the torque transfer capabilities, the force of the spring 680 (or the force from the fluid pressure in the chamber 664 used to overcome the spring 680 ) may be selected to provide a particular compression force between the clutch ring 677 and the engagement surface 637 . In some embodiments, the spring 680 may provide a force (to bias the clutch ring 677 and the engagement surface 637 toward one another) of approximately 700 lbs, 800 lbs, 900 lbs, 1000 lbs, 1100 lbs, 1200 lbs, 1300 lbs, 1400 lbs, 1500 lbs, or greater. The displacement of the spring 680 may be different depending upon the wear of the clutch ring 677 , so in some embodiments, the force from the spring 680 may be in the range of approximately 800 lbs to approximately 1400 lbs. For example, the spring 680 may provide a force of approximately 1100 lbs to approximately 1400 lbs when a substantially unworn clutch ring 677 is pressed against the engagement surface 637 . In the embodiment depicted in FIGS. 5-7 , the spring 680 may provide a force of approximately 1250 lbs when a substantially unworn clutch ring 677 is pressed against the engagement surface 637 . When the clutch ring 677 becomes substantially worn after repeated use, the displacement of the spring 680 may be different so that the compression force provide from the spring is lower. For example, the spring 680 may provide a force of approximately 800 lbs to approximately 1100 lbs when a substantially worn clutch ring 677 is pressed against the engagement surface 637 . In the embodiment depicted in FIGS. 5-7 , the spring 680 may provide a force of approximately 1000 lbs when a substantially worn clutch ring 677 is pressed against the engagement surface 637 .
Accordingly, by making appropriate selections from (i) the conical angle A, (ii) the coefficient of friction at the interface between the clutch ring 677 and the engagement surface 637 , (iii) the force from the spring 680 , and (iv) other such factors, the clutch member 600 may have a torque rating of approximately 2700 in-lbs, 2800 in-lbs, 2900 in-lbs, 3000 in-lbs, or more, and particular embodiments may provide torque ratings in the range of approximately 3000 in-lbs to approximately 5000 in-lbs—including torque ratings in the ranges of approximately 3200 in-lbs to approximately 4000 in-lbs and approximately 4000 in-lbs to approximately 5000 in-lbs. In some embodiments of a clutch member 600 having a conical angle A of approximately 30 degrees, having a clutch ring 677 having a static coefficient of friction of approximately 0.4, and having a spring force of approximately 1250 lbs when the clutch ring 677 is substantially unworn, the clutch member 600 may have torque ratings in the range of approximately 3200 in-lbs to approximately 4000 in-lbs. For example, a clutch member 600 that had a clutch ring 677 comprising Trimat MR8728 material (supplied by Trimat Ltd.) with a static coefficient of friction of approximately 0.4, had a conical angle A of approximately 30 degrees, and had a spring force of approximately 1250 lbs (when the clutch ring 677 was substantially unworn) provided torque ratings of approximately 3540 in-lbs, 3648 in-lbs, 3780 in-lbs, 3444 in-lbs, 3576 in-lbs, and 3636 in-lbs.
In other embodiments, a clutch member 600 having a clutch ring material with a greater static coefficient of friction (e.g., comprising Aramid materials supplied by either Trimat Ltd. or Scan Pac Mfg., Inc., Trimat TF100 material, or the like) may provide greater torque ratings. For example, some embodiments of a clutch member 600 may have a clutch ring 677 with a static coefficient of friction of approximately 0.5 (e.g., comprising Trimat TF100 material), may have a conical angle A of approximately 30 degrees, and may have a spring force of approximately 1250 lbs when the clutch ring 677 is substantially unworn, and such a clutch member 600 may have torque ratings in the range of approximately 4000 in-lbs to approximately 5000 in-lbs. Because a greater coefficient of friction may increase the frictional interface between the clutch ring 677 and the engagement surface 637 , some embodiments of the clutch member 600 may have a torque rating greater than 5000 in-lbs.
Thus, some embodiments of the clutch member 600 may provide torque ratings of approximately 2700 in-lbs, 2800 in-lbs, 2900 in-lbs, 3000 in-lbs, or more. Particular embodiments may provide torque ratings in the range of approximately 3000 in-lbs to approximately 5000 in-lbs—including torque ratings in the ranges of approximately 3200 in-lbs to approximately 4000 in-lbs and approximately 4000 in-lbs to approximately 5000 in-lbs.
It should be understood that the drive member 500 may have a configuration other than a drive pulley shown in FIGS. 5-7 . For example, the drive member 500 may be a shaft or gear that is powered by a motor. In such embodiments, the clutch member 600 may have a mounting configuration to removably attach to the shaft or gear or may have an adapter member connected therebetween.
In other embodiments, the output member 622 of the clutch member 600 may be configured to receive an output device other than fan blades. For example, the output member 622 may be configured to connect with other components that are to be selectively rotated, such as output shafts, gears, brake systems, and the like.
In yet another embodiment, the spring 680 that biases the piston portion 620 in an axial direction is not limited to a single, coiled spring shown in FIGS. 5-7 . Rather, the spring 680 can be any biasing member that can urge the piston portion 620 in the axial direction. A suitable biasing member may comprise one or more coil springs, leaf springs, gas springs, solid materials having appropriate elasticity properties, or the like.
Furthermore, some embodiments may include a clutch member configuration such that the spring 680 urges the piston portion 620 into the disengaged position (where the frusto-conical engagement surface 637 is offset from the frusto-conical clutch material 677 ). In such embodiments, the chamber 664 may be configured such that fluid pressure therein causes the piston portion 620 to shift toward engaged position (where the frusto-conical engagement surface 637 is pressed against the clutch material 677 ).
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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A clutch system may include in certain embodiments a clutch body attached to a drive member such as a drive pulley, wherein the clutch body may be removed from the drive member without disassembling the clutch body. In various embodiments, the clutch body may include two clutch plates which enclose a spring-loaded pneumatic reciprocating assembly that in operation causes the plates to selectively separate and engage one another. In certain embodiments, the clutch body may be readily attached to a associated drive pulley in a single step by installation of a single set of fasteners.
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BACKGROUND OF THE INVENTION
This is a continuation-in-part of copending application, Ser. No. 004,695, filed Jan. 19, 1979, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a flexible tube in combination with an energy-carrying conductor or conductors which is or are preferably, but not exclusively, adapted for use as a suction hose in combination with electrically-driven vacuum cleaning apparatus.
DESCRIPTION OF THE PRIOR ART
While the present invention has particular use as a suction hose in combination with vacuum cleaning equipment, such as a conventional tank or canister-type vacuum cleaner, it is to be understood that its particular application will be limited only to the end needs of the ultimate user.
Hoses of this type are well-known in the art, as represented in the patent literature. Illustrations are exemplified in the following United States patents: electrical conductors extending generally parallel to the axis of the hose, as shown in U.S. Pat. Nos. 3,965,526 and 4,064,355; alternative designs of electrical conductors extending along the axis or spirally wound, but not used as structural support, as in U.S. Pat. Nos. 3,277,231 and 3,715,454; electrical conductors in single or parallel configuration extending in a spiral fashion along the hose and utilized additionally as a hose-reinforcing element, as in U.S. Pat. Nos. 2,890,264 and 3,917,499; and electrical conductors which may or may not act as reinforcing elements which are embedded or otherwise carried in convoluted strips which overlap in helical fashion to form the hose, as in U.S. Pat. Nos. 2,516,864; 2,695,631; and 3,273,600. While these hoses are presumed to work well for their intended purposes, they are illustrative of a very large number of designs that have been developed to overcome problems in the art.
Experience has indicated that the following problems exist in such prior art hoses. Wires which are used as structural supporting members in the hose, primarily to resist radial crushing thereof, generally are positioned in such a manner that they cause the hose to have undue wear, which considerably decreases the life span of the hose. When such support wires are also electrical conductors, e.g., see U.S. Pat. No. 3,917,499, one area of their insulation is held exposed by the unyielding support wire to the severest area of wear, cut, or puncture, thus opening electrically live conductors to the grasp of the human hand. Realizing such limitations, other hoses have been designed so that the wires are utilized solely for their current-carrying characteristics, and the hose is otherwise formed to obtain maximum support and wear resistance through other means. The result generally is a bulky profile, which lacks economy in the use of material. Even when these problems are overcome, manufacture of the hose is complicated in that the current-carrying conductors must be appropriately handled during formation of the hose or in other steps in its production. In addition, such production techniques may limit the number or type of conductors that are used.
A further limitation in prior art hose exists in rigid retention of the electric conductors in the hose. If a pin or other subject should puncture the hose adjacent the conductor, there is a large probability that the puncturing instrument will contact the conductor, because the conductor has no capability to be deflected and move within the hose.
SUMMARY OF THE INVENTION
The present invention avoids or overcomes these and other deficiencies, drawbacks or problems by providing for a simply manufactured hose having electromagnetic energy-carrying conductors therein. Briefly, the hose comprises a strip which is helically wound into a tubular form with one of the strip's margins secured to an adjacent margin at adjoining convolutions of the strips. At least one cavity is formed in one of the strip margins in which the electromagnetic energy-carrying conductor is carried. For a single strip, there may be double or triple conductors. For a plurality of strips extending helically in parallel, one conductor may be placed in each cavity. It is preferable that the wire be loosely held within the cavity; however, it is possible to extrude the profile with the wire therein. A preferred use of such a hose is in combination with vacuum cleaning apparatus.
It is, therefore, an object of the present invention to provide for a hose with energy-carrying conductors in which the conductors are not a primary contribution to the supporting structure of the hose.
Another object is to provide for maximum structural support of the hose profile commensurate with maximum flexibility thereof.
Another object is to provide for conductors which are designed solely for their energy-carrying characteristics without regard to the support of the structure so that the hose may be tailored to use of the best electrical conductors or other electromagnetic means carried by the hose.
Another object is to provide for a means by which the flow path of the electromagnetic current is separate from the flow path of fluid flowing through the hose.
Another object is to provide for protection of the conductors from abrasion and wear, as well as to increase the amount of insulation above the conductors.
Another object is to provide space in the hose to allow for rolling or sliding of the conductor to aid in avoiding puncture by pins and the like.
Another object is to provide for a multiple profile hose which permits the use of one or a multiple of conductors therein.
Another object is to provide for ease and efficiency of manufacture of such a hose.
Another object is to provide for such ease and economy of manufacture both in extruding the profile and in convoluting the hose.
Another object is the use of such a hose in combination with vacuum cleaning apparatus.
Other aims and objects, as well as a more complete understanding of the present invention, will appear from the following explanation of exemplary embodiments and the accompanying drawings thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a cleaning apparatus equipped with the hose assembly of the present invention;
FIG. 2 is an enlarged plan view of the hose assembly depicted in FIG. 1;
FIG. 3 is a cross-sectional view of a portion of the hose depicted in FIG. 2 showing how convoluted strips are interengaged to form a hose wall section, as well as to show how electrical conductors are carried in specially made cavities therein;
FIG. 4 is a modification of the hose strip depicted in FIG. 3;
FIG. 5 illustrates the preferred machine and method for fabricating the hose depicted in FIGS. 2 and 3, with FIG. 5a being an enlargement of a part of the machine;
FIGS. 6 through 8 are cross-sectional views of steps in manufacturing the hose, taken along lines 6--6, 7--7, and 8--8, respectively, of FIG. 5;
FIG. 9 is a plan view of another embodiment of the hose assembly usable in the cleaning apparatus depicted in FIG. 1;
FIGS. 10-15 are cross-sectional views of portions of five embodiments of the hose illustrated in FIG. 9 showing how convoluted strips are interengaged to form hose wall sections with electrical conductors; and
FIG. 16 is a cross-sectional view of a portion of a hose similar to that depicted in FIG. 10 but applied to the hose of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts a preferred use of the present invention in which it comprises a component of a cleaning apparatus 10. As is conventional, cleaning apparatus 10 includes a vacuum pump housing or canister 12 communicating with a vacuum head 14 by means of a suction hose assembly 16. Canister 12 contains the vacuum pump with its drive motor, a vacuum chamber, a filter bag, controls and other components of a conventional vacuum cleaning device. The vacuum pump motor is connected to an electrical supply by a cord 18. Electrical wires from cord 18 extend into a conventional hose attachment with electrical socket 20, while a similarly conventional hose attachment with electrical socket 22 extends from vacuum head 14.
As shown in FIG. 2, hose assembly 16 includes a pair of mating hose attachments 24 which mechanically connect to hose attachments and sockets 20 and 22. Electrical pins 26 or the equivalent in hose attachment 24 respectively are coupled to the electrical sockets included within hose attachments 20 and 22. Because canister 12, vacuum head 14, and the various hose attachments and electrical sockets are conventional in the art, further description thereof will be dispensed with, it being recognized that vacuum head 14 includes an electric motor for driving one or more brushes, beater bars or similar moving devices which are intended to facilitate movement of dirt from the surface to be cleaned into the suction head.
Hose assembly 16 further comprises a hose 28 having electrical or electromagnetic energy-carrying conductors therein. The hose comprises one or more strips 30 which are helically wound so that one strip margin is secured to an adjacent strip margin at adjoining convolutions.
One such configuration is depicted in FIG. 3 which comprises a pair of strips 30a and 30b. Prior to convoluting of the strips into a hose, a strip 30a is secured to a strip 30b at their respective margins and, thereafter, the parallel strips are convoluted into the hose, as will hereinafter become better understood. The strips are preferably extruded to provide cavities 32a and 32b respectively at first strip margins 34a and 34b, and generally hook-shaped covers 36a and 36b respectively, defining the second strip margins of strips 30a and 30b.
All cavities are similarly formed and each comprises a generally U-shaped channel 40 having a base 42, a first side wall 44 extending from the base at the end of the strip edge, a second side wall 46 spaced from the first side wall and also extending from the base, and a top wall 48 hinged at 50 to first side wall 44. Hinge 50 generally comprises a necked-down portion of the strip which is formed during extrusion. As shown in FIG. 3, hinge 50 acts to facilitate bending of top wall 48 so that it will easily overlie and close channel 40 by coming into contact with second side wall 46. Both the bent and unbent configurations of top wall 48 are illustrated in FIG. 3.
Lying within respective cavities 32a and 32b are electrical conductors 52a and 52b. Bare wires may be placed within the cavities, if the strip material is of insulative material; however for double protection, wires 52a and 52b may have insulation material 54 thereon. Thus, any possible leakage of conductive fluid from the inside of hose 28 into cavity 40 will not result in a short circuit between wires or the carrying out of electric current to the human touch. In this respect, it is preferred that top wall 48 be bonded by a bonding agent 57 to second side wall 46, as well as to adjacent portions of hook-shaped covers 36a and 36b. The bonding material is preferably limited to the ends of walls 46 and 48 and the adjacent end leg portions 37 of covers 36a and 36b so that the hose will bend and flex much in the manner that is described in U.S. Pat. No. 3,255,780, whose principles of construction and flexibility are incorporated herein. Thus, those elements, for example of strip 30a in FIG. 3 identified by indicia 43a and 45a connecting base 42 with an intermediate leg portion 39, impart flexibility and support to hose assembly 16. Accordingly, elements 43a and 45a and leg portion 39 and their connecting hinge-like corners, including the corner between portions 37 and 39, may be termed flexible elements. Also, element 45a, portion 37 and walls 44 and 46 may be termed support elements in that they help to resist radially-exerted crushing forces on hose assembly 16. Equivalent elements appear in the embodiments of the remaining figures. Although not critical, any bonding material which may also adhere to intermediate leg portion 39 is not desired because it decreases flexibility of the hose.
It is further possible to utilize three or more strips, rather than those two which are depicted in FIG. 3, if it is necessary that there be more than two wires. For example, it may be necessary to utilize a third grounding wire as well as other wires which may be connected to an "on-off" switch. Therefore, it is to be understood that the concept of the present invention is not to be limited to use of a pair of strips but to one or more strips.
Furthermore, as shown in FIG. 4, a single strip 130 may be utilized in which a single large cavity 132 may incorporate a pair of wires 152 which, although shown as a pair of single wires, may be the conventional insulated double-wire configuration. Those double wires may be placed vertically, as shown, or horizontally and may include more than two conductors. In a like manner to that shown before, a bonding agent 156 secures together a top wall 148 and a second side wall 146, and the two walls to adjacent portions of a hook-shaped cover 136 in a manner similar to that discussed above with respect to FIG. 3. It is to be further understood, as a modification, that the single wire configuration of FIG. 3 may be combined with the double wire configuration of FIG. 4, utilizing a pair of parallelly extending strips.
If desired, wires 52a and 52b, and 152 may be extruded at the time strips 30 and 130 are formed.
The preferred method of forming the hose, such as shown in FIG. 3, is described with reference to FIGS. 5 through 8. This assembly is with reference to a pair of strips 58 and 60, each of which is formed by conventional extrusion operations. Strip 60 is fed between a pair of rollers 62 and 64 configured as shown in FIG. 6 to properly handle strip 60 as it passes therethrough. While passing through rollers 62 and 64, a wire 66 is also combined so that strip 60 with wire 66 therein approaches the next station at rollers 68 and 70.
At this point, strip 60 with its wire 66 therein is combined with strip 58. It is here that a first bonding agent 72 is applied to join a cavity margin of strip 60 with a hook-shaped cover of strip 58. The combination of strips 58 and 60 then proceeds to a further pair of rollers 74 and 76, which are configured similarly to rollers 68 and 70 and which permit insertion of a wire 78 therein.
From rollers 74 and 76, strips 58 and 60 in parallel formation are convoluted upon themselves as they pass around a mandrel 80, guided by its several rollers 82. The rollers have a general shape or configuration as depicted in FIG. 8, but with a pitch that would permit parallelly formed strips 60 and 58 to be helically wound into tubular form, with one strip margin secured to an adjacent margin at adjoining convolutions. In addition, a further bonding material 84 is inserted between the hook-shaped margin of strip 60 and the cavity margin of strip 58.
It is an important aspect in the method of forming the hose that, as hose strips 58 and 60 are wrapped or convoluted into the desired hose shape, top walls 48 will naturally bend into closure with second side walls 46. A deflector 86 with angled end 88 (see FIG. 5a) and/or the shape of the rollers start or urge bending of the top walls in the proper closing direction, as illustrated by the phantom position 48' of the top wall. Such natural tendency of the top walls to bend occurs if hinge 50 is above the area center of gravity 90 of the strip.
While such a configuration of roller pairs 62 and 64, and 74 and 76, and mandrel-rollers 80 and 82 cooperate to form a hose configuration such as depicted in FIG. 3, it is obvious that other configurations of roller and mandrel-roller pairs are suitable for producing single strip hose configurations or hose configurations comprising three or more strips. It is to be understood, of course, that the pitch of the convolutions, for a given strip cross-sectional configuration, becomes flatter and less acutely angled to the axis of the hose. Since the number of strips used in parallel affects the flexibility of the hose, such considerations as number of strips and strip configurations should be taken into consideration when a hose of particular flexibility is desired.
A modified hose assembly 116 is shown in FIG. 9 having a rounded, rather than square appearance. It comprises a hose 128 having electrical or electromagnetic energy-carrying conductors therein. The hose comprises one or more strips 230, 330, 430, 530, 630, or 730 (see FIGS. 10-15) which are helically wound so that one strip margin is secured to an adjacent strip margin at adjoining convolutions. A similar strip 830 (FIG. 16) is squared which, therefore, will form the hose configuration shown in FIG. 2.
Several similar, but modified, configurations are depicted in FIGS. 10-15 which respectively comprise pairs of strips 230a and 230b, 330a and 330b, 430a and 430b, 530a and 530b, 630a and 630b, and 730a and 730b. Prior to convoluting of the strips into a hose, a strip 230a, 330a, etc., is secured to a strip 230b, etc., at their respective margins, and, thereafter, the parallel strips are convoluted into the hose, as previously described with respect to FIGS. 5-8. To avoid needless repetition, all references to numerals of the "200" series of FIG. 10 are understood to apply likewise to the "300" through "800" series of FIGS. 11-16.
The strips are preferably extruded to provide cavities 232a and 232b respectively at first strip margins 234a and 234b, and generally hook-shaped covers 236a and 236b defining second strip margins respectively of strips 230a and 230b.
All cavities are similarly formed and each comprises a generally U-shaped channel 240 having a base 242, a first side wall 244 extending from the base at the end of the strip edge, a second side wall 246 spaced from the first side wall and also extending from the base, and a top wall 248 hinged at 250 to first side wall 244. Hinge 250 generally comprises a necked-down portion of the strip which is formed during extrusion. As shown in FIG. 10 (as well as FIGS. 11-16) hinge 250 acts to facilitate bending of top wall 248 so that it will easily overlie and close channel 240 by coming into contact with second side wall 246. Both the bent and unbent configurations of top wall 248 are illustrated.
Especially where hook-shaped covers 236a and 236b are rounded as shown in FIGS. 10-15, pegs 249, 349, 449, 549' and 549", 649, 749' and 749", and 849 extend from one of hook-shaped covers or top walls or both, and towards and into contact with the opposing top or cover, to ensure that hook-shaped covers 236a and 236b, etc., are properly supported by and above wall 248, etc., and to maintain the desired external hose appearance. The particular position of the peg is not critical, and it further acts as a dam for containing bonding material 256, etc., as precisely as possible. The preferred location of the peg is illustrated in FIG. 10, to afford maximum flexibility to the hose.
The use of pegs not only keeps the wire chamber, formed by the U-shaped channel and the top wall, closed, but also is used to provide other important advantages. It or they reinforce the upper part of the hose crown defined by the hook-shaped covers, and it can keep the bonding material at a vertical edge.
Lying within the respective cavities 232a and 232b are electrical conductors 252a and 252b. Bare wires may be placed within the cavities, if the strip material is of insulative material; however for double protection, wires 252a and 252b may have insulation material 254 thereon. Thus, any possible leakage of conductive fluid from the inside of hose 228 into cavity 240 will not result in a short circuit between wires or the carrying out of electric current to the human touch. In this respect, it is preferred that top wall 248 be bonded by a bonding agent 256 to second side wall 246, as well as to adjacent portions of hook-shaped covers 236a and 236b. Depending upon the particular construction defined by the pegs, the bonding material is to a greater or lesser extent limited to the ends of walls 246 and 248 and the adjacent end leg portions 237 of covers 236a and 236b so that the hose will bend and flex much in the manner that is described in U.S. Pat. No. 3,255,780, whose principles of construction and flexibility are incorporated herein.
It is to be further understood that the specific designs of the channel or cavity of FIGS. 3, 4, and 10-16 are the preferred designs, and, if desired, it may not be necessary to utilize a top wall such as top wall 48, but to dispense with it. It also may not be necessary to retain one side wall 46, but use side wall 44 in combination with top wall 48, using additional bonding material to compensate for lack of the second side wall. Furthermore, other strip configurations, such as suggested in U.S. Pat. No. 3,255,780, may be utilized; see, particular, FIGS. 10 through 18 thereof with the electrical conductor being placed at or adjacent to the bonding locations of those configurations. As still another modification, the design depicted in copending U.S. patent application, Ser. No. 678,547, filed Apr. 20, 1976, may be used in lieu of the presently described design.
Although the invention has been described with reference to particular embodiments thereof, it should be realized that various changes and modifications may be made therein without department from the spirit and scope of the invention.
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The hose, which is particularly adapted for use with an electrically-driven vacuum cleaning apparatus, comprises a substantially air-tight, flexible tube which is pneumatically coupled between the vacuum pump and the suction head. The suction hose comprises one or more elongated strips which is or are helically wound into tubular form. In a pair of parallelly placed strips, the strip margin of the first strip is secured to an adjacent margin of the second strip at adjoining convolutions of the strips. Electrical conductors are carried by the strips within helically extending cavities formed at the edges or margins of each of the strips and are a portion of that means which electrically couples the cleaning brush to the electrical power supply.
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This is a division, of application Ser. No. 809,051, filed Dec. 12, 1985 now U.S. Pat. No. 4,730,048.
BACKGROUND OF THE INVENTION
It has long been known that the naturally-occurring semisynthetic opium alkaloids, or "opiates", manifest their pharmacologic effects both centrally and peripherally. The primary target sites for the former effects are the brain and the spinal cord. For example, morphine is used as an analgesic, to induce sleep in the presence of pain and to suppress cough. The major peripheral sites are located in the gastrointestinal tract. Thus, opiate agonists also inhibit gastric emptying and the propulsive motor activity of the intestine. The anti-diarrheal action of opiate analgesics such as morphine is a manifestation of this effect. Efforts to minimize the central nervous system (CNS) effects of opiates while retaining a useful level of activity in peripheral tissues have resulted in the preparation of quaternary derivatives of narcotic antagonists and agonists by addition of a second alkyl substituent on the ring nitrogen atom. See D. R. Brown et al., Neuropharmacology, 24, 181 (1985). However, while these compounds generally exhibit reduced penetration of the blood brain barrier, they also exhibit a substantially-lowered overall affinity for opiate receptors.
Therefore, a need exists for opiates which exhibit high levels of activity with respect to gastrointestinal tissue, without exhibiting substantial levels of access to the CNS. A need also exists for opiates with characteristically high levels of antidiarrheal activity which exhibit low levels of undesirable CNS effects such as drowsiness, lowered respiratory activity and addictive potential. A further need exists for gut-specific antagonist opiates which can selectively reverse the peripheral activity or protect against the peripheral activity of agonist narcotics.
SUMMARY OF THE INVENTION
The present invention is directed to novel compounds of the general formulae I or II: ##STR2## wherein R is (C 1 -C 5 )alkyl, C 3 -C 6 (cycloakyl)alkyl, aryl, aralkyl or trans-(C 2 -C 5 )alkenyl; Z is H or OH, R' is (C═O)--A(B)(C), wherein A is selected from the group consisting of (C 1 -C 5 )alkyl, (C 2 -C 5 )alkenyl and (C 2 -C 6 )alkoxy(alkyl); B is selected from the group consisting of H, amino and a (C 1 -C 5 )alkyl group optionally substituted with CO 2 H, OH, or phenyl; and C is CO 2 H, SO 3 H amino or guanidino; and R" is selected from the group consisting of NH--A(B)(C) or guanidino. Preferably, R is (C 1 -C 3 )alkyl, alkyl or cyclopropylmethyl, B is H or amino, and C is CO 2 H or guanidino.
Thus, preferred opiates of formula I are prepared by attaching hydrophilic, ionizable moieties R' and R" to the 6-amino group of naltrexamine [I: R═(cyclopropyl) methyl, Z═OH and R'═H] or oxymorphamine (I: R═CH 3 , Z═OH and R'═H). The opiates of formula II can be prepared by converting the 6-keto-group of oxymorphone (III: R═CH 3 , Z═OH) or naltrexone [III: R═(cyclopropyl)methyl, Z═OH] to the ionizable, hydrophilic group (R"N═) by a Schiff base reaction with a suitable amino-compound. ##STR3##
In a similar fashion, deoxy-opiates of formulae I and II wherein Z═H may be prepared from readily available starting materials, as described hereinbelow.
The configuration of the 6--(R'NH) group of formula I may be alpha- or beta- with respect to the plane of the cyclohexyl ring to which it is attached. Alternatively, the compounds of formula I may comprise mixtures of both configurations of the R'NH group.
Since the groups R'NH-- and R"N═ contain one or more acidic or basic substituents that contribute to the ability of molecule to substantially ionize at physiologic pH's or at the pH of the gut (pH 1-7), they are expected to confer low lipid solubility on opiates I and II, thereby minimizing their access to the CNS. Thus, the compounds of the present invention are expected to exhibit greater selectivity toward peripheral mammalian tissues such as gut tissue, and concomitantly lower CNS activity.
The agonist compounds of the present invention may be employed to modify intestinal function with minimal abuse potential or other CNS side effects when administered orally. Compounds in this series which are opiate antagonists could be used to selectively block the constipating effects of narcotic analgesics. Also, the compounds of the present invention may be useful to modulate endocrine andrrenal activity with minimal CNS action.
Therefore, the invention also comprises the pharmaceutically acceptable salts of the biologically-active opiates of formulae I and II, together with a pharmaceutically acceptable carrier for administration in effective non-toxic dose form. Pharmaceutically-acceptable amine salts may be salts of organic acids, such as acetic, lactic, malic, or p-toluene sulphonic acid, and the like as well as salts of pharmaceutically acceptable mineral acids, such as phosphoric, hydrochloric or sulfuric acid, and the like. Pharmaceutically-acceptable carboxylate salts of the present opiates may also be employed, e.g., amine salts, such as dimethylamine and triethylamine salt, the ammonium salt, tetrabutylammonium salt, cyclohexylamine salt, dicyclohexylamine salt; and metal salts, e.g., mono-, di- and tri-sodium salt, mono-, di- and tripotassium salt, magnesium salt, calcium salt and zinc salt.
These physiologically acceptable salts are prepared by methods known in the art. Metal salts can be prepared by reacting a metal hydroxide with the free acid. Examples of metal salts which can be prepared in this way are salts containing Li, Na, K, Ca, Mg, Zn, Mn and Ba. A less soluble metal salt can be precipitated from a solution of a more soluble salt by addition of a suitable metal compound. Thus for examples, Zn, Mg and Mn salts can be prepared from the corresponding sodium salts. The metal ions of a metal salt of a carboxylic acid can be exchanged by hydrogen ions, other metal ions, ammonium ion and ammonium ions substituted by one or more organic radicals by using a suitable cation exchanger.
In clinical practice, the opiates or the salts thereof will normally be administered orally or parenterally, by injection or infusion, in the form of a pharmaceutical preparation comprising the active ingredient in combination with a pharmaceutically acceptable carrier which may be a solid, semi-solid or liquid diluent or an ingestible capsule. The compound or its salt may also be used without carrier material. As examples of pharmaceutical preparations may be mentioned tablets, suspensions, liposomes, and the like. Usually the active substance will comprise between about 0.05 and 99%, or between 0.1 and 95% by weight of the preparation, for example between about 0.5 and 20% of preparations intended for injection and between about 0.1 and 50% of preparations intended for oral administration.
Other salts may be prepared and then converted by conventional double decomposition methods into pharmaceutically acceptable salts directly suitable for the treatment of diarrhea in mammals, or for the relief of constipation caused by opiate analgesics.
DETAILED DESCRIPTION OF THE INVENTION
The synthesis of representative compounds of formula I is outlined in Table I.
TABLE I__________________________________________________________________________ ##STR4## ##STR5## ##STR6##__________________________________________________________________________
The starting materials 13 and 14 were prepared as described by L. M. Sayre et al., in J. Org. Chem., 45 3366 (1980), the disclosure of which is incorporated by reference herein.
Compounds 1, 2, 4, 8, 10 and 11 can be prepared by reaction of the parent 6-amino opiates 13 or 14 with the appropriate anhydride.
The carboxymethyl derivative 7 was prepared by reaction of bromoacetic acid (BrCH 2 CO 2 H) with 14 in the presence of a dialkylamine. Similarly, other (alpha-bromosubstituted)carboxylic acids would be expected to react with the 6-amino group of 13 or 14 to yield analogs of 13 or 14 substituted by an alpha-amino acid which is bound to the 6-position of the opiate via the alpha-amino group. Thus, the R'NH-substituent of 7 is a glyc-N-yl moiety. Other preferred R'HN-- substituents introduced in this manner include alanin-N-yl, serin-N-yl, threonin-N-yl, valin-N-yl, leucin-N-yl, isoleucin-N-yl, phenylalanin-N-yl, tyrosin-N-yl, aspartic acid, glutamic acid, lys-N-yl and arginin-N-yl, as well as other synthetic and naturally-occuring alpha-amino acids. Therefore, R'NH-- is preferably a naturally-occurring "amino acid-N-yl radical".
The fumaramic acids 3 and 9 were prepared by coupling the half ester of fumaric acid (HO 2 CCH t ═CHCO 2 Et, Aldrich Chemical Co., Milwaukee, Wis.) with 13 or 14, respectively in the presence of dicyclohexylcarbodiimide (DCC) and hydroxybenztriazole (HOBt) to yield fumaramate esters 3a and 9a. The fumaramate esters were subjected to hydrolysis in an alcoholic solution of an alkali metal hydroxide such as ethanolic sodium hydroxide (NaOH).
The aspartyl esters 6 and 12, were obtained by coupling PhCH 2 O 2 CCH 2 CH(NHBoc)CO 2 H (Chemical Dynamics Corp., South Plainfield, N.J.) with 14 or 13 in the presence of DCC and HoBt, followed by deprotection with acid (HCl) to remove the Boc group and removal of the benzyl (PhCH 2 ) group by hydrogenolysis (H 2 ,Pd catalyst).
The arginyl derivative 5 was prepared by coupling HO 2 C--CH(NHBoc)(CH 2 ) 3 NH(C═NH)NHNO 2 (Boc-Arg(NO 2 )), Aldrich Chemical Co., Sigma Chemical Co., St. Louis, Mo.) with 13 in the presence of DCC and HOBt, followed by deprotection of the arginyl moiety with acid (HCl) and hydrogenolysis.
Opiates of formula I within the scope of the present invention can also be prepared from the starting o material of formula I wheren and R═allyl, Z═OH and R'═H, which is prepared as described by J. B. Jiang et al., in J. Med. Chem., 20, 1100 (1977), the disclosure of which is incorporated by reference herein.
Opiates of formula I wherein Z═H can be prepared by reaction sequences analogous to those shown in Table I from starting materials such as I [R═(cyclopropyl)methyl, Z═H, R'═H] as disclosed by J. W. Schoenecker, Ph.D. Thesis, University of Minnesota, 1984, or I [R═CH 3 , Z═H, R'═H] as disclosed by R. Bognar et al., Acta Chim. Acad. Scient. Hung., 58, 203 (1968), the disclosures of which are incorporated by reference herein.
Opiates of formula II can be prepared by reacting the 6-keto group of oxymorphone (III: R═CH 3 , Z═OH) or naltrexone [III:R═(cyclopropyl)methyl, Z═OH] with hydrazine derivatives such as H 2 NNH(C 1 -C 4 )alkyl--CO 2 H to form the corresponding hydrazones wherein R"═NH(C 1 -C 4 )alkyl--CO 2 H. Hydrazones of formula II were prepared wherein R═(cyclopropyl)methyl, Z═OH and R"═NHCH 2 CO 2 H (15) or NHC(═NH)NH 2 (16) by reacting naltraexone-HCl with alpha-hydrazinoacetic acid and aminoguanidine, respectively.
Hydrazones of formula II wherein Z═H can be prepared analogously from starting materials such as hydromorphone (III: R═CH 3 , Z═H; Mallinckrodt, Inc., St. Louis, Mo.) or opiate III [R═(cyclopropyl)methyl, Z═H], prepared as disclosed by M. Gates et al., J. Med. Chem., 7, 127 (1964), the disclosure of which is incorporated by reference herein. Hydrazones of formula II wherein Z═H and R═allyl can be prepared from naloxone (III: Z═H, R═allyl).
The invention will be further described by reference to the following detailed examples, wherein melting points were determined with a Thomas-Hoover capillary melting point apparatus and are uncorrected. Elemental analyses were performed by M--H--W Laboratories, Phoenix, Ariz. All analytical results were within ±0.4% of the theoretical values. IR spectra were recorded on a Perkin-Elmer 281 spectrophotometer. NMR spectra were recorded on either JNM-FX 90Q FT NMR spectrometer, or Nicolet 300 MHz NMR spectrometer with tetramethylsilane as internal standard. Mass spectra were obtained on an AEI M5-30 (EI, 20 eV) or Finnigan 4000 (CI, NH 3 , positive or negative). All R f values were obtained on Analtech silica gel TLC plates.
EXAMPLE 1
Preparation of Compounds 1, 2, 4, 8, 10, 11
The appropriate acid anhydride (succinic, maleic, glutaric, or 3-oxyglutaric) (0.33 mmol) was dropped over a 1.0 hr period into a dimethylformamide (DMF) (2.5 ml) solution containing 0.33 mol of naltrexamine 14 or oxymorphamine 13. After stirring for an additional 3.0 hr at 25° C., the mixture was poured into ether (50 ml) and the precipitate was collected by filtration. Crystallization from acetone or aqueous acetone afforded the pure acids, 1, 2, 4, 8, 10, or 11.
EXAMPLE 2
Preparation of Fumaramic Acids 3 and 9
To a mixture of the dihydrochloride of 14 or 13 (0.62 mmol), triethylamine (TEA) (0.35 g, 2.48 mmol) and dimethylformamide (2 ml) that had been stirred at 25° C. for 15 min, was added fumaric acid monoethyl ester (0.089 g, 0.68 mmol) and 1-hydroxybenzotriazole (HOBt) (0.189 g, 1.24 mmol). Dicyclohexylcarbodiimide (DCC) (0.192 g, 0.93 mmol) was then added to the cooled mixture (0° C.) which was then stirred for 1.0 hr and at 25° C. for 10 hr. The reaction mixture was poured into water (50 ml) containing sodium carbonate, and the mixture was extracted with ethyl acetate (5×25 ml). After removal of the solvent in vacuo, the product was chromatographed on silica gel (EtOAc-MeOH-Me 3 N, 90:10:0.5) to afford the ethyl ester intermediates, 3a or 9a, respectively, which were hydrolyzed in ethanolic NaOH (0.5 N, 5 ml) at 25° C. for 10 hr. The mixture was adjusted to pH 8 with 1N HCl and the solvent was removed in vacuo. The product (3 or 9) was purified by chromatography on silica gel (EtOAc-MeOH-NH 4 OH, 70:30:4).
EXAMPLE 3
Synthesis of Aspartic Acid Derivatives 6 and 12
A mixture of the dihydrochloride of 14 or 13 (0.67 mmol), triethylamine (0.38 g, 2.67 mmol), and dimethylformamide (2 ml) was stirred at 25° C. for 15 min. To this was added PhCH 2 O 2 CCH 2 CH(NHBoc)CO 2 H (0.237 g, 0.73 mmol) and 1-hydroxybenzotriazole (0.180 g, 1.33 mmol), and the mixture cooled to 0° C. Dicyclohexylcarbodiimide (0.206 g, 1 mmol) was then added, and stirring was continued at 0° C. for 1.0 hr and at 25° C. for 10 hr. The mixture was filtered and the filtrate was poured into water (50 ml) containing sodium carbonate (0.2 g). The product was extracted with ethyl acetate (EtOAc) (4×25 ml). After removal of the solvent in vacuo, the residue was treated with HCl to afford products (6 or 12, respectively) as the dihydrochloride salts.
EXAMPLE 4
β-Naltrexamineacetic acid (7)
β-Naltrexamine.2HCl (0.415 g, 1 mmol) was suspended in acetonitrile (7 ml) and diisopropylethylamine (0.61 g, 3.5 mmol) was added. After 10 min, bromoacetic acid (0.153 g, 1.1 mmol) was added and the reaction mixture was allowed to stand at 25° C. for 10 hr. After removal of solvent, the solid residue was recrystallized from hot isopropanol containing 1% MeOH to afford 0.265 g (66%) of 7, mp>280°.
EXAMPLE 5
Arginyl-β-naltrexamine (5)
β-Naltrexamine.2HCl (0.415 g, 1 mmol) was suspended in DMF (3 ml), and TEA (0.3 ml) was added. After cooling to 0° C., Boc-Arg(NO 2 ) (0.319 g, 1 mmol), HOBt (0.405 g, 3 mmol) and DCC (0.210 g, 1 mmol) were added. The reaction was stirred at 0° C. for 1.0 hr and at 25° C. for 12 hr. The mixture was filtered and washed with DMF (0.5 ml). To the filtrate, 10% aqueous NaHCO 3 (50 ml) was added, and the mixture was extracted with ethyl acetate (3×50 ml). The ethyl acetate was dried over magnesium sulfate and the solvent was evaporated in vacuo. The residue was triturated with ethyl ether, and the solid that formed was filtered and washed with ether. The nitroarginyl intermediate (0.610 g, 95% yield), mp 153°-156° C., was dissolved in 4N HCl in ethyl acetate (10 ml), and after 20 min, 10 ml of ethyl acetate was added. This solid was filtered and washed with ethyl acetate. Yield, 0.510 g (73%); mp 258° C. (dec); R f ═0.18 (nBuOH-AcOH-H 2 O, 4:1:1).
Arg(NO 2 )-β-naltrexamine.2HCl (400 mg, 0.57 mmol) was dissolved in methanol (15 ml) and 10% Pd/C catalyst (50 mg), and conc. HCl (0.3 ml) were added. After hydrogenation for 24 hr, the catalyst was removed by filtration and the solvent was evaporated in vacuo. The residual solid was precipitated by addition of EtOAc to afford 370 mg (96%) of 5, mp>280° C., R f ═0.12 (nBuOH-HOAc-H 2 O).
EXAMPLE 6
Boc-α-hydrazinoacetic acid
To a cooled methanolic (40 ml) (0° C.) solution of NaOH (3.2 g, 0.08 mol) and Boc-hydrazine (5.3 g, 0.04 mol) was added bromoacetic acid (5.6 g, 0.04 mol) in methanol (10 ml). The solution was refluxed for 3.0 hr, 50 ml of water was added, and the mixture was extracted twice with ethyl acetate. The aqueous phase was acidified to pH 4 with citric acid (3.4 g), and extracted with ethyl acetate. The organic phases were collected and dried (MgSO 4 ). The solvent was removed by evaporation, and the resulting solid was washed twice with ethyl ether. Yield, 3.5 g (46%); mp 144°-146° C.; R f ═0.51 (nBuOH-H 2 O-HOAc, 4:1:1).
EXAMPLE 7
α-Hydrazinoacetic acid
The Boc-α-hydrazinoacetic acid (1.90 g, 0.01 mol) was dissolved in 4N HCl in ethyl acetate (20 ml). The precipitate that formed was isolated by decantation and was triturated with ethyl ether. Yield, 1.25 g (100%); R f ═0.1 (nBuOH-H 2 O-HOAc, 4:1:1).
EXAMPLE 8
Naltrexazoneacetic acid (15)
Naltrexone.HCl (0.377 g, 0.001 mol) was added to a methanol (2 ml) solution containing α-hydrazinoacetic acid (0.127 g, 1 mmol) and triethylamine (0.30 ml, 2.2 mmol), and the mixture was stirred for 12 hr at 25° C. The precipitate that formed was filtered and washed with methanol (0.5 ml), isopropanol (2 ml), and ethyl ether (2 ml). Crystallization from methanol afforded 0.274 g (66%) of 15, mp 340° (dec), R f ═0.21 (nBuOH-HOAc-H 2 O, 4:1:1).
EXAMPLE 9
Naltrexazone iminosemicarbazone (16)
Aminoguanidine carbonate (138 mg, 1 mol) was suspended in ethanol (25 ml) containing concentrated HCl (0.1 ml), and the solvent was removed. The residual solid was dissolved in ethanol (50 ml), naltrexone.HCl (377 mg, 1 mmol) was added, and the mixture was heated under reflux for 0.5 hr. The solid product was collected by filtration and washed with hot ethanol to afford 451 mg (96%) of 16. R f ═0.39 (nBuOH-HOAc-H 2 O, 2:2:1). Analysis. Calc for C 21 H 38 N 5 O 3 .2HCl.2C 2 H 5 OH: C, 53.27; H, 7.53; N, 12.43. Found: C, 52.91; H, 7.75; N, 12.80.
The structure and physical characterization of opiates 1-12 is summarized on Table II, below.
TABLE II__________________________________________________________________________Compound Formula I (Z═OH) Yield Elem.No. R R' % mp, °C. R.sub.f Empirical Formula Anal__________________________________________________________________________1 CH.sub.2 CH(CH.sub.2).sub.2 COCH.sub.2 CH.sub.2 COOH 85 245-248 0.22.sup.a C.sub.24 H.sub.30 N.sub.2 O.sub.6.0.75H.sub.2 O C,H,N2 " CO(CH.sub.2).sub.3 COOH 62 >260 0.43.sup.b C.sub.25 H.sub.32 N.sub.2 O.sub.6.C.sub.2 H.sub.4 O.sub.2.0.5H.sub.2 O3 " ##STR7## 86 >280 0.25.sup.a C.sub.24 H.sub.28 N.sub.2 O.sub.6.H.sub.2 O C,H,N4 " COCH.sub.2 OCH.sub.2 COOH 75 >250 0.40.sup.c C.sub.24 H.sub.30 N.sub.2 O.sub.7.2H.sub.2 O C,H,N5 " COCH(NH.sub.2)(CH.sub.2).sub.3 NHC(NH)NH.sub.2 70 >280 0.12.sup.d C.sub.26 H.sub.39 N.sub.6 O.sub.4.5HCl C,H,N6 " COCH(NH.sub.2)CH.sub.2 COOH 71 >280 0.18.sup.d C.sub.24 H.sub.31 N.sub.3 O.sub.6.2.3HCl.2H.sub.2 C,H,N,Cl7 " CH.sub.2 COOH 66 >280 0.15.sup.d C.sub.22 H.sub.28 N.sub.2 O.sub.5.3H.sub.2 O C,H,N8 CH.sub.3 COCH.sub.2 CH.sub.2 COOH 64 218-220 0.15.sup.e C.sub.21 H.sub.26 N.sub.2 O.sub.6.1.5H.sub.2 O C,H9 " ##STR8## 79 >280 0.27.sup.f C.sub.21 H.sub.24 N.sub.2 O.sub.6.2H.sub.2 O C,H,N10 " ##STR9## 67 294-296 0.24.sup.g C.sub.21 H.sub.24 N.sub.2 O.sub.6.1.5H.sub.2 O C,H,N11 " COCH.sub.2 OCH.sub.2 COOH 47 240-242 0.14.sup.e C.sub.21 H.sub.26 N.sub.2 O.sub.7.1.5H.sub.2 O C,H12 " COCH(NH.sub.2)CH.sub.2 COOH 75 >280 0.05.sup.e C.sub.21 H.sub.27 N.sub.3 O.sub.6.2HCl.2H.sub.2 C,H,N__________________________________________________________________________ .sup.a EtOAc--MeOH--H.sub.2 O--NH.sub.4 OH (75:20:5:2). .sup.b CH.sub.3 CN--H.sub.2 O--HOAc (83:17:3). .sup.c EtOAc--MeOH--NH.sub.4 OH (70:30:2). .sup.d nBuOH--HOAc--H.sub.2 O (4:1:1). .sup.e EtOAc--MeOH--NH.sub.4 OH (50:50:5). .sup.f EtOAC--MeOH--NH.sub.4 OH (70:30:4). .sup.g EtOAC--MeOH--NH.sub.4 OH (50:50:1).
EXAMPLE 10
Evaluation of Agonist and Antagonist Activity
Compounds 1-15 were evaluated for biological activity with respect to electrically-stimulated guinea pig ileum (GPI) preparations by the method of H. B. Rang, Brit. J. Pharmacol., 22, 356 (1964). The concentration-response relationship for agonism was compared to that of morphine, which was run as a control for each preparation. The antagonist potency was evaluated by the displacement of the morphine concentration-response curve to higher concentration in the presence of the antagonist. These values are expressed as a ratio of IC 50 values (IC 50 of morphine in the presence of the antagonist divided by the control IC 50 of morphine). The agonist and antagonist data obtained are summarized on Table III, below.
TABLE III______________________________________Agonist and Antagonist Activitieson the Guinea Pig Ileum Preparation. Agonism.sup.a Antagonism.sup.bCompound (Morphine = 1) (Morphine IC.sub.50 Ratio).sup.c______________________________________1 .sup.d 11.03 3 3.7.sup.e4 .sup.d 34.85 .sup.d 4.06 14.2 17 .sup.d 2.4.sup.e8 1.6 19 1.5 110 2.7 111 3.1 112 6.1 115 .sup.d 10016 29 .sup.f______________________________________ .sup.a Potency factors for the inhibition of contraction of the electrically stimulated guinea pig ileum relative to that of morphine (3 determinations). .sup.b Unless otherwise stated, the concentration of the ligand was 200 nM. .sup.c The factor by which the morphine concentrationresponse curve is shifted in a parallel fashion to higher concentration in the presence of the ligand (3 determinations). .sup.d Partial agonist; maximal response at 1 uM was 30-60% that of morphine. .sup.e Ligand concentration = 20 nM. .sup.f Unable to measure antagonism due to potent agonism.
All of the oxymorphamine derivatives 8-12 were determined to be more potent than morphine in inhibiting contraction of the GPI. It is likely that many of these compounds will possess substantial antidiarrheal activity. No morphine antagonist activity was observed with these compounds.
The naltrexamine derivatives 1-7 generally were observed to function as morphine antagonists. The aspartyl compound 6 was a possible exception to this generality. All of these compounds (1-7) possessed agonist activity, but 1, 4, 5 and 7 produced submaximal responses relative to morphine. These compounds are therefore classified as mixed agonist-antagonists, which may be useful to block the constipation caused by opiate analgesics.
The results of these studies indicate that it is possible to modify the C-6 position of a variety of opiates by introducing ionizable groups without compromising agonist activity. In fact, the N-methyl compounds all were highly potent agonists in the GPI and most of the N-cyclopropyl analogues were capable of shifting the morphine dose-response curves to higher concentration.
The fact that the attachment of polar groups (R') did not adversely affect the primary activity of many of the compounds make them excellent candidates for use in disorders of peripheral origin because access to the CNS would be expected to be substantially reduced from that of the parent unsubstituted agonist and antagonist.
It is apparent that many modifications and variations of this invention may be made without departing from the spirit and scope thereof. The specific embodiments described are given by way of example only and the invention is limited only by the terms of the appended claims.
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Gut-selective agonist or antagonist opiates of the formula: ##STR1## wherein R is (C 1 -C 5 ) alkyl, C 3 -C 6 (cycloalkyl)alkyl, aryl, aralkyl or trans-(C 2 -C 5 )alkenyl; Z is H or OH, R' is (C═O)-A(B)(C) wherein A is selected from the group consisting of (C 1 -C 5 )alkyl, (C 2 -C 5 )alkenyl and (C 2 -C 6 )alkoxy (alkyl); B is selected from the group consisting of H, amino and a (C 1 -C 5 )alkyl group optionally substituted with CO 2 H, OH or phenyl and C is CO 2 H, SO 3 H, amino or guanidino; and R" is selected from the group consisting of NH-A(B) (C) or is guanidino; and the pharmaceutically-acceptable salts thereof.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates to masts and methods for raising or erecting masts, particularly on offshore drilling platforms or at relatively inaccessible sites on land.
2. Description of the Prior Art
Several types of well masts have been used in connection with oil wells. Often, these masts have been portable for movement between well sites, particularly for offshore or remote area drilling. It has been customary to have masts of telescoping sections which can be extended one above the other to make a mast of desired height.
One type of mast took the form of two section telescoping masts with an upper section telescoped into a lower section. The entire assembly was transported as a unit from one location to the next. The telescoped mast sections as a unit made the unit heavy. Further, on arrival at the drilling site, the entire collapsed assembly was tilted up as a unit into vertical position, at which time the upper section was then extended. Tilting of the entire mast as a unit was undesirable both for load reasons and in that it caused damage and increased wear and tear on the mast structure.
A second type of portable mast used a three-section telescoping mast with an intermediate section and an upper section telescoped within a lower section. Other than the added section, the three-section mast operated in the manner of the two-section masts. Because of the added section, weight, load and hauling problems only increased.
U.S. Pat. No. 4,134,237, of which applicant Armstrong is an inventor, issued Jan. 16, 1979 and disclosed a third type of portable mast. This mast comprised a modular section mast having a lower or base section first mounted in a vertical position on a substructure. Upper and, if required, intermediate sections, were positioned one at a time as additional sections within the open side of the fixed vertical lower section. The additional sections were then extended upwardly, one at a time, from the lower section to form a fully extended mast of desired height. This type of mast, although affording advantages over telescoping masts, had several undesirable features. At the drilling site, the sections were stored in a horizontal position. Erection of the mast required lifting of each of the modular sections from the horizontal position to a vertical upright position prior to installing them in the lower section.
This latter type of mast structure suffered problems when raising the mast sections from the horizontal storage position to the upright position. In raising the mast sections, they were connected at the end to be the upper end with a lifting cable while in the storage position. As the lifting cable raised this end of the mast section, the other or free end of the lifted mast section dragged across the drilling platform or other well site surface, damaging both the well site surface and mast structure.
SUMMARY OF THE INVENTION
Briefly, according to the present invention, an improved well mast apparatus for use with a well platform is provided. The well mast apparatus comprises a lower mast section, and additional mast sections including at least an upper or second mast section and, if desired, one or more intermediate or third mast sections. The mast sections are provided with lifting rings or hooks positioned between their ends for balancing the mast sections in a horizontal position upon lifting and movement. Additionally, the additional mast sections are provided with a pivotable connector offset from the lifting ring for controlling and guiding pivotal movement of the upper mast section relative to the lower mast section.
The offset of the lifting ring from the pivotable connector and the lifting rings on the balanced horizontal second mast section operably guides the direction and speed of rotation of each of the additional sections relative to lower section as the mast apparatus of the present invention is being raised.
The well mast apparatus of the present invention provides a method to quickly and efficiently erect a mast structure while reducing damage to the mast sections during raising or erection.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and features of the invention will become more apparent by reference to the drawings which are appended hereto wherein like numerals indicate like parts and wherein an illustrative embodiment of the invention is shown, of which:
FIGS. 1, 2 and 3 are elevation views of a well mast apparatus according to the present invention during initial stages of its being raised or erected;
FIG. 4 is an elevation view taken at 90° from FIGS. 1, 2 and 3 during further stage of raising the well mast according to the present invention;
FIGS. 5, 6, 7, 8 and 9 are elevation views of a well mast according to the present invention during further stages of its being raised;
FIG. 10 is an elevation view of a well mast according to the present invention in its raised position;
FIGS. 11 and 12 are enlarged views of portions of the well mast of FIG. 10 disassembled from each other;
FIG. 13 is a view taken partly in cross-section along the lines 13--13 of FIG. 12;
FIG. 14 is an enlarged view of a portion of the structure of FIG. 12;
FIG. 15 is a view taken along the lines 15--15 of FIG. 2;
FIG. 16 is a view taken along the lines 16--16 of FIG. 15;
FIG. 17 is a view taken along the lines 17--17 of FIG. 2; and
FIG. 18 is a view taken along the lines 18--18 of FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The well mast structure of the present invention, indicated generally at 20 in FIG. 10, is adapted to be assembled or erected on a well drilling site. The well drilling site may be a foundation on the ground, a truck bed, an offshore platform, the upper section of another well mast structure or other suitable substructures. The preferred well mast structure 20 includes a lower or first mast section 22, and additional mast sections including at least an upper or second mast section 24, and, if required, one or more intermediate or third mast sections 26.
Though not shown, a conventional lifting crane is provided at the drilling site for lifting the mast sections as the mast 20 is being assembled. The lower mast section 22 is shown (FIG. 1) in a substantially horizontal position during an initial stage of assembling the mast structure 20. A lower end of mast section 20 is provided with a pivotable attaching means or mast shoes 28 on each of a pair of support legs 23 (FIGS. 1 and 2) for attachment to respective upright pedestals or stands 30 on a sub-base 32 at the well platform or drilling site. The support legs 23 of lower mast section 22 are connected at various positions along their longitudinal extent by lateral or cross-beams 25 (FIGS. 15 and 16). The pedestals 30 are adapted to fit within and be pivotally connected to mast shoes 28 by suitable connector bolts, pins or the like.
The lower mast section 22 also includes a pair of spaced, pivotal support legs 34 pivotally connected at their upper ends to frame members 43 and 44 (FIG. 15) of like construction to frame members 38 and 40 (FIGS. 17 and 18) mounted between support legs 23 and support members 36. The frame members 38 and 40, along with frame members 43, together with the upper cross-beams form a generally U-shaped box 45 at the upper end of the lower mast section 22. Further, no cross-beams are provided between either the spaced support legs 34 or the spaced support members 36. In this manner, an elongate, U-shaped receiving channel or slot 41 (FIG. 17) is formed in the lower mast section 22 once it is installed and raised (FIG. 2).
A mast shoe 34A (FIG. 1) is formed at the lower end of the mast section 20 on each of the pivotal support legs 34 for attachment to respective upright pedestals or stands 36 on the well drilling site 32. The pedestals 36 are adapted to fit within and be connected to the mast shoes 34A by suitable connector pins, bolts 36A or the like.
Prior to transport to the drilling site, the pivotal support legs 34 are each secured to their respective support legs 23 by ropes or other suitable means. The lower mast section 22 is then connected to a four part sling 48 including a pair of upper sling members 48a and a pair of lower sling members 48b beneath a crane hook 49. The lower mast section 22 is then lifted and moved to a position where the mast shoes 28 can be connected to the stands 30 by suitable pins or the like.
Once the mast shoes 28 are connected to the stands 30, the support legs 34 are released. They remain in position, however, because of temporary support legs or props 46, until lifting of the lower mast section 22 begins. The lower pair of sling members 48b are then disconnected from the support legs 23 and the crane hook 49 raised. As the crane hook 49 is raised, the lower mast section 22 is then tilted gradually upwardly by lifting forces imposed from the crane hook 49. Tilting continues with support legs 34 pivoted outwardly due to their weight until the support legs 23 are in the upright position shown in FIG. 2. At this point, the pivotal support legs 34 will be hanging generally vertically. They are then moved and pivoted forward to the position shown in FIG. 2 so that their mast shoes 34A may be connected to the stands 36, completing installation of the lower mast section 22.
The crane hook 49 is then connected by a lifting sling 47 to a lifting bar 50 on each of a pair of support legs 51 of the upper mast section 24. The bar 50 is preferably positioned at the horizontal centroid of mast section 24 so that during its lifting and movement, the mast section 24 will maintain a substantially horizontal position, as shown in FIG. 2. Mast section 24 maintains this balanced horizontal position when lifted from its horizontal storage position for connection to the mast section 22.
The upper mast section 24 is provided with a conventional crown platform 52 and crown block 54, its upper end 24A and a racking board 56 at its lower end 24B. A travelling block 58 is connected to the crown block 54 by a suitable strength of temporary rope line 60. The travelling block 58 is fixedly attached to the upper mast section during initial installation phases (FIG. 2). The upper mast section is also illustrated with a racking board support 56. The mast structure 22 is provided with the other usual conventional mast structure, such as ladders and the like, although not shown in the drawings to preserve clarity.
As best shown in FIGS. 2 and 3, a hook connector 62 is mounted on each of a pair of spaced, parallel support legs 64 laterally offset from the lifting ring 50 for controlling and guiding pivotal movement of the upper mast section 24 relative to the lower mast section 22, as will be set forth below.
The connector hooks 62 on mast section 24 are adapted to engage with pivot rods 65 (FIGS. 3, 15 and 16) and pivot within a corresponding set of pivot sockets (FIGS. 2 and 3) mounted with support plates 66 and 67 above support legs 23 of mast section 22 (FIGS. 15 and 16).
During raising of the mast 20, the upper section 24 is brought into a position (FIG. 3) where the connector hooks 62 are inserted into the pivot sockets 65 of lower mast section 22. After this connection is made, the force exerted by crane hook 49 is gradually removed and the mast section 24 is permitted to pivot slowly downwardly (FIG. 3) to a position within the lower mast section 22 (FIG. 4). Horizontally slideable latch pins 75 (FIGS. 15 and 17) are then moved inwardly to the position shown to insure that upper section 24 remains in telescoping position within lower mast section 22.
The rope line 60 is then connected to a conventional drilling line mounted on conventional draw works of the drilling platform. The rope line 60 is then used to pull the drill line from the draw works through the crown block 54 and travelling block 58 to complete their stringing up or reeving. Once this has been done, the crown block 54 is then connected through the drilling line to the draw works and the travelling block 58 is released to hang within the mast sections 22 and 24 (FIG. 4). Raising lines 70 which are fixedly attached at an upper end 70A and side portions of the upper end of mast section 22 are then passed over pulley wheels 74 (FIGS. 2, 3, 4 and 11) mounted at the lower end 24B of upper mast section 24 and attached to the travelling block 58 (FIG. 4). The draw works then reels up the drilling line to raise the travelling block 58. As the travelling block 58 moves upwardly (FIG. 5), the raising lines 70 pull the upper mast section 24 upwardly within the lower section 22. The latch pins 75 insure that this movement is a telescoping one. Upward telescoping movement of upper section 24 within lower section 22 continues to a point (FIG. 6) where suitable locking mechanisms, such as locking pins or wedges at the upper end 22A of mast section 22 may be used to connect with the lower end 24B of mast section 24 to interconnect the mast sections and lock them together.
If the desired mast requires only the lower section 22 and upper section 24, the mast 20 according to the present invention has now been assembled (FIG. 6) and raised for drilling operations. In some situations, however, a taller mast is needed, requiring that an intermediate mast section 26 (FIG. 7) be installed.
The intermediate mast section 26 (FIG. 7) has an upper end 26A (FIGS. 12, 13 and 14) and a lower end 26B (FIG. 7) with a lifting ring 76, positioned therebetween. One lifting ring 76 is positioned on each of support legs 77 on mast section 26 in a like manner to the lifting sling 47 of upper mast section 24, at the horizontal center of mass or centroid of the intermediate mast section 26. The upper end 26A end of intermediate mast section 26 includes a pivot pin 78 (FIG. 13) mounted between side plates 79 adjacent an upper end 77A of each of support legs 77. The pivot pins 78 are adapted to engaged connector hooks 86 (FIG. 11) mounted beneath support legs 51 at the lower end 24B of the upper mast section 24. The intermediate mast section 26 is installed to be raised by engaging its lifting ring 76 with crane hook 49 while mast section 26 is in its horizontal storage position. The mast section 26 is then lifted and moved, but maintains its horizontal position during such lifting and movement, due to the location of the lifting ring 76. The mast section 26 is then moved to a position as shown in FIG. 7 where each of the pivot pins 78 engages and fits within one of the hooks 86 detailed in FIG. 11 . The force exerted by crane hook 49 is gradually reduced, permitting the intermediate mast section 26 to descend to its lower position (FIG. 8). The interengagement of hooks 86 and pivot pins 78 permits controlled and guided pivotable movement of the intermediate mast section 26 relative to the lower mast section 22.
A pair of guide pulleys 88 are mounted on lower supports 90 between support legs 77 and 92 at the lower end 26B of intermediate mast section 26. The pulleys 88 are of like construction to the pulleys 74 on upper mast section 24.
A connector lug 94 (FIG. 12) is formed at an upper end 92A of support leg 92. The connector lug 94 is adapted to align with a connector lug 96 extending downwardly from the lower end 24B of upper mast section 24 (FIG. 11). In the lower position (FIG. 8), connector lugs 94 and 96 cannot be brought initially into contact with each other, due to the pivotal connection between pivot pins 78 and hooks 86.
Accordingly, the travelling block 58 is lowered within mast section 26 and connected to raising lines 70 which are passed over pulleys 88. The travelling block 58 is then raised, pivoting the upper end 26A of mast section 26 upwardly (FIG. 9) so that connector lugs 94 and 96 are aligned and can be locked together. The lock between the upper mast section 22 and lower mast section is then released, so that the travelling block 58 may be raised to lift mast sections 24 and 26 upwardly. Upward lifting of mast sections 24 and 26 continues until lock structure of like structure to that of mast section 24 at the lower end of 26B of mast section 26 is aligned with the lock structure at the upper end 22A of lower mast section 22. The mast sections 22 and 26 are then locked together at their locking structure, and the raising lines 70 released, completing the raising of the mast structure 20 (FIG. 10).
Various modifications and alterations in the disclosed apparatus and methods will be apparent to those skilled in the art of the foregoing description which does not depart from the spirit of the invention. For this reason, these changes are to be considered included in the appended claims. The appended claims recite the only limitation to the present invention, and the descriptive matter which is employed for setting forth the embodiments is to be interpreted as illustrative and not a limitation.
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A well mast apparatus is disclosed in the form of multiple, separately connectable sections including a lower mast section, an upper mast section and, if desired, several subsequent intermediate mast sections. The mast sections are provided with lifting rings positioned thereon for balancing the mast sections upon lifting. The upper mast section includes a connector offset from its lifting ring for controlling and guiding pivotal movement of the upper mast section relative to the lower mast section as the well mast is being raised. The lifting ring offset from the pivotable connector, which is interengaged between the fixed vertical lower section and the balanced horizontal second mast section, guides the direction and speed of rotation of the second mast section relative to the lower mast section during installation.
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GOVERNMENT RIGHTS
This invention was made with Government support under Collaborative Technology Alliances Power & Energy Consortium contract DAAD19-01-2-0010 awarded by the Army Research Lab. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
A power source supplies a current at a voltage to a load for a period of time. Characteristics of the load typically define the kind of power source that is appropriate. Electronic circuits may demand a relatively small current for an extended period of time. A mechanical device may demand a short burst of relatively high current to generate a powerful motion. Some loads, like an electric vehicle may require smaller currents for motion over a flat surface and a larger current to move up an incline.
Electric powered vehicles may employ large lead acid batteries to provide energy for their traction systems and operating systems. A battery of this type typically delivers from 24 to 48 volts. A traction system may be powered to move an electric powered vehicle around the workplace under the control of an operator or a computer. Traction systems may draw large currents from the DC bus during acceleration or when moving up an incline, but normally demand lower currents for extended periods of time. Operating systems, such as a lift system, may consume a significant portion of the stored power during normal truck operation. When lifting heavy loads, the operating systems may demand large currents for short periods.
A conventional lift truck will typically operate from 5 to 6 hours on a fully charged battery. When the battery voltage drops below a certain level the truck is driven to a battery station where the depleted battery is removed and a fully charged replacement battery is installed. This operation typically requires from 20 to 30 minutes during which the truck and operator are nonproductive.
Efforts have been made to improve the vehicle designs, particularly in ways that will increase the productive period of the battery. For example, the battery may be recharged during truck operation by an alternator, generating charging currents with motions of the traction and lift systems. While this approach does recover some of the energy, lead acid batteries are inefficient energy recovery devices. A large portion of the regenerated energy is dissipated as heat and lost. Periods when large currents are drawn during truck operation significantly limit battery life.
As can be seen, there is a need for power sources capable of providing large currents in short bursts and lower currents over an extended period of time. A hybrid power source consisting of a high power source and a high energy source can result in a high energy and as well as high power device when the load duty cycle of each component power source is actively managed. For example: a fuel-cell, which is a high energy density device, may be hybridized with a supercapacitor, a high power device, to construct such a source. A supercapacitor or ultracapacitor is an electrochemical capacitor that has an unusually high energy density when compared to common capacitors.
SUMMARY OF THE INVENTION
In one aspect of the invention, a hybrid power system comprises a power source and a power storage element receiving energy from said power source, wherein said power storage element stores energy received from said power source while simultaneously providing energy to a load.
In another aspect of the invention, a method of operating a hybrid power system comprises charging a first capacitance bank, charging a second capacitance bank. The first charged capacitance bank is connected to a load and the second charged capacitance bank is connected to an energy source. The first capacitance bank is then disconnected from the load and connected to the energy source. The second capacitance bank is connected to the load. The first capacitance bank is then connected to the load and the second capacitance bank is disconnected from the load. The second capacitance bank is then connected to the energy source.
In a further aspect of the invention, a hybrid power system comprises a fuel cell, a DC/DC converter electrically connected to the fuel cell and converting the energy level of the energy supplied by the fuel cell. A first switch is electrically connected to the DC/DC converter or some other DC source. A first and second capacitance banks are electrically connected to the first switch and a second switch respectively. A controller is connected to the first switch and the second switch. The controller monitors the charge levels of the first supercapacitor and the second supercapacitor and controls the first switch and the second switch in response to the charge levels. A load is electrically connected to the second switch. When the first switch connects the DC/DC converter to the first capacitance bank, the second switch connects the second supercapacitor to the load. When the first switch connects the DC/DC converter to the second capacitance bank, the second switch connects the first capacitance bank to the load.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram depicting a hybrid power system in accordance with an embodiment of the present invention;
FIG. 2 is a block diagram depicting a controlled hybrid power system in accordance with an embodiment;
FIG. 3 is a block diagram depicting a controlled dual storage hybrid power system in accordance with an embodiment;
FIG. 4 is a block diagram depicting a converted hybrid power system in accordance with an embodiment;
FIG. 5 is a block diagram depicting a supercapacitor bank hybrid power system in accordance with an embodiment;
FIG. 6 is a flow diagram depicting a simplified process of operating a hybrid power system in accordance with an embodiment; and
FIG. 7 is a flow diagram depicting a process of operating a monitored hybrid power system in accordance with an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Broadly, the present invention is a hybrid power system to provide power for electrical vehicles, robots and other electrical devices having varieties of power demands.
A typical power source optimally provides either low currents or large currents. A capacitor, which is a higher power density but lower energy density device, is typically capable of providing a large current for a short period. A fuel cell, which is a higher energy density but lower power density device, may provide smaller currents for a lengthy period of time. A hybrid power source may include a power source providing low currents for extended periods of time integrated with a power storage element capable of providing large currents for short periods of time. A super-capacitor bank periodically recharged by fuel cells may provide the load with the necessary currents, as needed, resulting in a power source with optimal levels of energy and power densities.
With reference to FIG. 1 , a hybrid power system 100 in accordance with an embodiment is shown. A power source 102 may provide energy to power storage element 104 . A fuel cell may be used as the power source 102 for the hybrid power system 100 . Fuel cells may provide a steady source of power for as long as the cells remain fuelled. Batteries such as lithium primary or secondary batteries may be used as a power source 102 . The power storage element 104 may be charged by the energy provided by the power source 102 . Supercapacitors may be used as a power storage element 104 . Power storage element 104 may store the energy provided by the power source 104 until the energy may be demanded by a load 106 .
With reference to FIG. 2 , a controlled hybrid power system 200 in accordance with an embodiment is shown. A power source 102 may provide energy to a power storage element 104 where the energy may be stored. Load 106 may draw power as needed from the power storage element 104 . Further power storage 110 such as a battery may be charged. A controller 108 may be connected to the power storage element 104 to monitor charge levels of the power storage element 104 , and connect power source 102 to the power storage element as needed.
With reference to FIG. 3 , a controlled dual-storage hybrid power source 300 in accordance with an embodiment is shown. A pair of power storage elements 112 and 114 may be charged by power from a power source 102 . The load 106 may receive power from the power storage elements 112 and 114 . A first switch 116 may route power from the power source 102 to the first power storage element 112 until the first switch 116 may be instructed by the controller 108 to route the power from the power source 102 to the second power storage element 114 . Using the first switch 116 , the controller 108 may regulate the flow of power from the power source 102 to charge the power storage elements 112 and 114 alternately. A second switch 118 may alternately route power from the power storage elements 112 and 114 to the load 106 . The controller 108 may control the switches 116 and 118 so that when the first power storage element 112 may be charged, the load 106 may draw power from the second power storage element 114 and when the second power storage element 114 may be charged, the load may draw power from the first power storage element 112 . The controller 108 may be an oscillator. In accordance with an embodiment of the invention, controller 108 may include a programmed microprocessor.
Typically, each of the power storage elements 112 and 114 may be identical capacitance banks. Alternately, the power storage elements 112 and 114 may be capacitance banks of various capacitance values. Each capacitance bank 112 , 114 may include a specified number of capacitor cells in series, where the number of cells may be selected to comply with specified load voltage requirements. In addition, the capacitance banks 114 , 116 may consist of parallel strings of cells, where the number of cells and strings may be chosen to provide the necessary capacitance value. The specifications may be determined with reference to appropriate capacitor bank weight, volume, cost, charge voltage, current and timing.
In addition to controlling the switches 116 and 118 , the controller 108 may monitor various system voltages such as the voltage level of the capacitance banks 114 , 116 and system currents, such as the current level supplied by the fuel cell 102 , of the hybrid power source 300 . The controller 108 may operate a load switch 118 to connect and disconnect the power storage elements 112 and 114 to and from the load 106 so that power may be available to the load at all times. A ‘make before break’ switching scheme may be implemented accordingly.
With reference to FIG. 4 , a converted hybrid power system 400 in accordance with an embodiment is shown. A power source 102 may include fuel cells receiving fuel from a fuel storage unit 124 . The power source 102 may provide energy at a given voltage level that may be different from the voltage levels needed to charge the power storage elements 104 and support the load, so the energy from the power source 102 may be sent through a first converter 120 . The first converter 120 may be typically a standard DC/DC converter to convert the input voltage level 134 to an output voltage level 136 . A first switch 116 may route the energy received from the converter 120 to one of the capacitance banks 114 , 116 in the power storage elements 104 in accordance with control signals received from controller 108 . A load switch 118 may route the energy from one of the capacitance banks 114 and 116 in the power storage elements 104 in accordance with control signals received from the controller 108 . The power storage elements 104 may provide energy at a given voltage level that may be different from the voltage levels needed by the load 106 , so the energy from the power storage elements 104 may be sent through a second converter 122 . The second converter 122 may be typically a standard DC/DC converter to convert the input voltage level 138 to an output voltage level 140 . The controller 108 may receive signals from the fuel storage 124 , power source 102 and power storage elements 104 indicating fuel levels, energy levels and charge levels.
With reference to FIG. 5 , a supercapacitor bank hybrid power system 500 in accordance with an embodiment is shown. A fuel cell 102 may generate energy which may be then stepped-up by a DC/DC converter 120 . The energy may be provided to the sources 142 , 148 of MOSFETs 126 , 128 (Metal Oxide Semiconductor Field Effect Transistor). The drains 146 , 152 of MOSFETs 126 , 128 may alternately provide energy to one of the capacitance banks 130 , 132 . Likewise, load switch 118 may alternately provide current from one of the capacitance banks 130 , 132 to the load 106 . The MOSFETs 126 , 128 may be controlled by controller 108 connected to gates 144 , 150 . The load switch 118 may be controlled by controller 108 .
MOSFET switches 126 , 128 may be used to apply charge energy to individual capacitance banks 130 , 132 such that while one bank 130 may be providing energy to the load, the other bank 132 may be charged by energy from the fuel cell 102 . While two capacitance banks 130 , 132 may be shown in the present embodiment, it should be understood that any number of capacitance banks could be implemented in accordance with another embodiment. The switching sequence of the MOSFETs 126 , 128 may be managed by the controller 108 connected to gates 144 , 150 . The switches 126 , 128 , 118 may be implemented using MOSFETs or any suitable switch compatible with electronic control and providing appropriate resistance.
With reference to FIG. 6 , a process 600 of operating a hybrid power system 500 in accordance with an embodiment is shown. Initially, a first capacitance bank 130 may be charged at function block 602 and a second capacitance bank 132 may be charged at function block 604 . The load may be connected the first capacitance bank at function block 606 . After a predetermined time, typically sufficient to charge the second capacitance bank 132 and before the first capacitance bank 130 may be completely discharged, the load 106 may be connected to the second capacitance bank 132 at function block 608 . The first capacitance bank 130 may be disconnected from the load 106 at function block 610 . The first capacitance bank 130 may be connected to the fuel cell 102 and may be charged at function block 612 . After the predetermined time elapses, a fully charged first capacitance bank 130 may be connected to the load 106 at function block 614 . The second capacitance bank 132 may be disconnected from the load 106 at function block 616 and connected to the fuel cell 102 to be charged at function block 618 . The process may cycle after the predetermined period elapses, connecting the load 106 to the second capacitance bank 132 at function block 608 .
With reference to FIG. 7 , a process 700 of operating a hybrid power system 500 in accordance with an embodiment is shown. The capacitance bank 130 , 132 may be initially charged at function block 702 . The first capacitance bank 130 may be connected to the load 106 at function block 704 . The charge level of the first capacitance bank 130 may be monitored by the controller 108 at function block 706 . The charge level of the first capacitance bank 130 may be compared to a predetermined threshold at decision block 708 . Until the charge level reaches the threshold, the process follows the NO path and continues monitoring the charge level. When the charge level reaches the threshold, the process follows the YES path. The second capacitance bank 132 may be connected to the load 106 at function block 710 . The first capacitance bank 130 may be disconnected from the load 106 at function block 712 and connected to the fuel cell 102 to be recharged at function block 714 . The second capacitance bank charge level may be monitored at function block 716 . The charge level of the second capacitance bank 132 may be compared to a predetermined threshold at decision block 718 . Until the charge level reaches the threshold, the process follows the NO path and continues monitoring the charge level. When the charge level reaches the threshold, the process follows the YES path. The first capacitance bank 130 may be connected to the load 106 at function block 720 . The second capacitance bank 132 may be disconnected from the load 106 at function block 722 and connected to the fuel cell 102 to be recharged at function block 724 . The cycle repeats and the first capacitance bank charge level may be monitored at function block 706 .
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A hybrid power system is comprised of a high energy density element such as a fuel-cell and high power density elements such as a supercapacitor banks. A DC/DC converter electrically connected to the fuel cell and converting the energy level of the energy supplied by the fuel cell. A first switch is electrically connected to the DC/DC converter. First and second supercapacitors are electrically connected to the first switch and a second switch. A controller is connected to the first switch and the second switch, monitoring charge levels of the supercapacitors and controls the switching in response to the charge levels. A load is electrically connected to the second switch. The first switch connects the DC/DC converter to the first supercapacitor when the second switch connects the second supercapacitor to the load. The first switch connects the DC/DC converter to the second supercapacitor when the second switch connects the first supercapacitor to the load.
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PRIORITY CLAIM
[0001] This application is a continuation in part of U.S. application Ser. No. 10/698,322 filed Oct. 31, 2003, the entire contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates to formulations for topical use comprising antibiotics in combination with anti-inflammatory steroids for treating ophthalmic infections and attendant inflammation. More specifically, this invention relates to pharmaceutical ophthalmic formulations comprising a pH stabilizing amount of an aminoglycoside and a steroid.
BACKGROUND OF THE INVENTION
[0003] Topical steroids such as corticosteroids are commonly used for anti-inflammatory therapy of the eye, especially for treating inflammatory conditions of the palpebral or bulbar conjunctiva, cornea and anterior segment of the globe. Common therapeutic applications for steroids include allergic-conjunctivitis, acne rosacea, superficial punctate keratitis and iritis cyclitis. Steroids also are used to ameliorate inflammation associated with corneal injury due to chemical or thermal burns, or penetration of foreign bodies. Such conditions may result from surgery, injury, allergy or infection to the eye and can cause severe discomfort.
[0004] Despite their therapeutic advantages, topical ocular use of corticosteroids is associated with a number of complications, including posterior subcapsular cataract formation, elevation of intraocular pressure, secondary ocular infection, retardation of corneal wound healing, uveitis, mydriasis, transient ocular discomfort and ptosis. Numerous systemic complications also may arise from the topical ocular application of corticosteroids. These complications include adrenal insufficiency, Cushing's syndrome, peptic ulceration, osteoporosis, hypertension, muscle weakness or atrophy, inhibition of growth, diabetes, activation of infection, mood changes and delayed wound healing.
[0005] Topical steroids for treating ocular inflammations can be based on soft drugs. Soft drugs, as is known in the art, are designed to provide maximal therapeutic effect and minimal side effects. By one approach, synthesis of a “soft drug” can be achieved by structurally modifying a known inactive metabolite of a known active drug to produce an active metabolite that undergoes a predictable one-step transformation in-vivo back to the parent, inactive metabolite (see, U.S. Pat. Nos. 6,610,675, 4,996,335 and 4,710,495 for soft steroids). “Soft drugs” therefore are biologically active chemical components characterized by predictable in vivo metabolism to non-toxic derivatives after they provide their therapeutic effect. Formulations of cortico steroids suitable for ophthalmic use are known. For example, U.S. Pat. Nos. 4,710,495, 4,996,335, 5,540,930, 5,747,061, 5,916,550, 6,368,616 and 6,610,675, the contents of each of which is incorporated by reference herein, describe soft steroids and formulations containing soft steroids.
[0006] Antibiotic agents for use in treating ophthalmic infections are also known. For example penicillins, cephalosporins and aminoglycosides such as amikacin, gentamicin and tobramycin are known to be useful in treating infections of the eye. Tobramycin is commercially marketed and well recognized as an effective antibiotic. This particular anti-infective is recognized as active against the common bacterial eye pathogens: Staphylococci , including S. aureus and S. epidermidis , including penicillin resistant strains, Streptococci , including S. pneumoniae, Pseudomonas aeruginosa, Escherichia coli, Klebsiella pneumoniae, Enterobacter aerogenes, Proteus mirabilis, Morganella morganii, Haemophilus influenzae, H. aegyptius, Acinetobacter calcoaceticus and some Neissaria species. Tobramycin's antimicrobial activity is provided by its ability to bind with the 30S ribosomal subunit and alter protein synthesis, thus leading to the death of the microbial organism.
[0007] It has previously been suggested that the steroid loteprednol etabonate (LE) can be combined with antibiotics such as tobramycin. However, there has been no suggestion of the amount of tobramycin to be used in combination with LE to provide a desired therapeutic effect of both active agents. There has also been no detailed description of a combined formulation having satisfactory properties for storage and use of the combination of tobramycin and LE.
[0008] It is known that formulations containing steroids can experience stability problems. Such stability problems include clumping and other undesirable changes upon storage. U.S. Pat. No. 5,916,550 describes the use of C 2 -C 7 aliphatic amino acids to control pH depression of aqueous suspensions of LE on prolonged storage. Therefore, the need to provide pharmaceutical formulations of steroids that are stable upon storage is well recognized. One of the factors used to evaluate stability of pharmaceutical formulations is pH. When there is a dramatic change in the pH of a pharmaceutical formulation over time, the ability of the formulation to be effectively stored and retain its pharmaceutical activity after storage becomes questionable. It is known to add buffers to certain pharmaceutical formulations in an effort to maintain the stability of the formulation during storage. Examples of buffers include borate buffers, phosphate buffers, etc. Although these buffers are useful in stabilizing pH, they do not demonstrate pharmaceutical activity. Therefore, it would be desirable to use a single material to provide pH stabilizing activity and desired anti-infection activity to pharmaceutical ophthalmic formulations containing a steroid.
SUMMARY OF THE INVENTION
[0009] It has surprisingly been discovered that the an aminoglycoside, such as tobramycin, when present in a pH stabilizing amount, helps to stabilize steroid containing formulations over time to provide better storage characteristics.
[0010] This invention provides novel compositions of matter containing a combination of water-soluble and water-insoluble drugs suitable for therapeutic use. The invention provides pH stable aqueous suspensions of water-insoluble drugs that remain in such a state even after extended periods of storage.
[0011] More particularly, the invention is directed to aqueous suspensions of steroids such as loteprednol etabonate in combination with aminoglycosides such as tobramycin suitable for therapeutic use in the eye, ear, or nose. The aqueous suspensions of steroid and aminoglycoside are surprisingly pH stable and can remain in a pH stable state for extended periods of storage.
[0012] Formulations comprising the broad spectrum aminoglycoside antibiotic in combination with a steroid loteprednol provide pharmaceutical ophthalmic formulations that not only allow for the simultaneous treatment of inflammation and infection in a patient in need of treatment thereof, but also results in a pharmaceutical ophthalmic formulation having increased stability, as measured by decreased change in pH as compared to similar steroid formulations that do not contain a pH stabilizing amount of an aminoglycoside.
[0013] Further provided herein is a topical eye drop medication indicated for steroid-responsive inflammatory ocular conditions for which a corticosteroid is indicated and where superficial bacterial ocular infection or risk of bacterial ocular infection exists. The medication comprises a steroid/aminoglycoside ophthalmic suspension. The use of this medication is indicated where the risk of superficial ocular infection is high or where there is an expectation that potentially dangerous numbers of bacteria will be present in the eye.
[0014] Also provided herein is a therapeutically effective composition comprising a steroid in an amount effective to provide a therapeutic benefit to a patient to whom the composition is administered and a pH stabilizing amount of an aminoglycoside, wherein the aminoglycoside is present in an amount effective to stabilize the pH of the composition relative to the pH of a similar formulation without the aminoglycoside.
[0015] Also provided herein is a method of treating a patient having inflammatory ocular conditions for which a corticosteroid is indicated and where superficial bacterial ocular infection or risk of bacterial ocular infection exists, the method comprising topically applying to a patient in need of treatment thereof therapeutic amount of a pharmaceutical composition comprising a ph stabilizing amount of a broad spectrum aminoglycoside antibiotic in combination with the a steroid.
[0016] Having briefly summarized the invention, the invention will now be described in detail by reference to the following specification and non-limiting examples. Unless otherwise specified, all percentages are by weight and all temperatures are in degrees Celsius.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Therapeutic suspensions of steroids for ophthalmic or otolaryngological uses are made by aseptic preparation. Purity levels of all materials employed in the suspensions of the invention exceed 98%. The suspensions of the invention are prepared by thoroughly mixing the steroid (component (A)), aminoglycoside (component (B)), suspending agent (component (C)), and surface active agent (component (D)). Optionally, tonicity agents (component (E)) and preservatives (component (F)) may be included.
[0018] Steroids of component (A), preferably soft steroids, most preferably LE, can be employed. Also other steroids such as beclomethasone, betamethasone, fluocinolone, fluorometholone, exednisolone, prednisolone and rimexolone may be employed. The suspensions of component (A) of the invention have a particle size of about 0.1-30μ, preferably about 1-20μ, most preferably about 2-10 microns in mean diameter. LE in this size range is commercially available from suppliers such as the Sipsy Co., (Avrille, France).
[0019] The aminoglycoside component (B) is pharmaceutical grade. Aminoglycosides are a well-characterized family of antimicrobial agents and include, for example, gentamicin, neomycin, paromomycin, kanamycin, tobramycin, netilmicin and amikacin. Tobramycin of this grade is commercially available from suppliers such as the Biogal Pharmaceutical Works (Debrecen, Hungary). Component (B) is preferably present in an amount that is effective to stabilize the pH of the composition relative to the pH of a similar composition without Component (B). Therefore the amount of Component (B) may vary depending upon the individual composition. Determining a pH stabilizing amount of an aminoglycoside for a particular composition can be readily achieved through routine experimentation and is within the purview of one skilled in the art.
[0020] The nonionic polymer of component (C) can be any nonionic water-soluble polymer. Typical compounds such as PVP, PVA, HPMC or dextran can be used at a concentration of about 0.01-2%, and preferably between about 0.4 to 1.5%, and more preferably between 0.4 to 1%. Viscosity increased above that of simple aqueous solutions may be desirable to increase ocular absorption of the active compound, to decrease variability in dispensing the formulation, to decrease physical separation of components of a suspension or emulsion of the formulation and/or to otherwise improve the ophthalmic formulation. Such viscosity builder agents include as examples polyvinyl alcohol, polyvinyl pyrrolidone, methyl cellulose, hydroxy propyl methylcellulose, hydroxyethyl cellulose, carboxymethyl cellulose, hydroxy propyl cellulose or other agents known to those skilled in the art. Povidone is preferably used as a suspending agent in the finished product and the water-soluble grades are routinely used in pharmaceuticals as a viscosity enhancing agent. The viscosity of aqueous solutions of the water-soluble grades of povidone depends on the average molecular weight. A subtle change in the grade and concentration of the suspending agent can yield the desired characteristics. Povidone comes in a variety of grades, of which some are water soluble. Povidone K-90 is the highest molecular weight water-soluble viscosity grade Povidone. This material is listed as Povidone, USP 90,000. The high molecular grade povidone dissolves much more slowly than the lower molecular weight grade.
[0021] Component (D) is a surface-active agent that is acceptable for ophthalmic or otolaryngological uses. Preferably, this surfactant is non-ionic. Useful surface active agents include but are not limited to polysorbate 80, tyloxapol, TWEEN 80 (ICI America Inc., Wilmington, Del.), PLURONIC F-68 (from BASF, Ludwigshafen, Germany) and the poloxamer surfactants. These surfactants are nonionic alkaline oxide condensates of an organic compound that contains hydroxyl groups. The concentration in which the surface active agent may be used is only limited by neutralization of the bactericidal effects on the accompanying preservatives, or by concentrations that may cause irritation. Preferably, the concentration of component (D) is about 0.05 to 1%, and more preferably 0.1 to 0.6% by weight based on the weight of the suspension. Compositions of the present invention having a molar ratio of (A):(C):(D) between about 1:20:1 and about 1:0.01:0.5 are entirely suitable.
[0022] The tonicity agents of component (E) can be nonionic diols, preferably glycerol, in sufficient amounts to achieve isotonicity. The nonionic tonicity agents can be present in an amount of about 2 to 2.8% by weight, and preferably about 2.2 to 2.6%.
[0023] The nonionic polymeric compounds of component (C), and the surface active agents of component (D) have good solubility in water, have sufficient number of hydroxyl groups to interact with the steroid, and have mild effects on the viscosity of the suspension. Final viscosity should not exceed 80-centipoise.
[0024] The suspensions of the invention also may include additional therapeutic drugs such as drugs for treating glaucoma, anti-inflammatory drugs, anti-cancer drugs, anti-fungal drugs and anti-viral drugs. Examples of anti-glaucoma drugs include but are not limited to timolol-base, betaxalol, athenolol, levobanolol, epinenephrin, dipivalyl, oxonolol, acetazilumide-base and methazalomide. Examples of anti-inflammatory drugs include but are not limited to non-steroids such as piroxicam, indomethacin, naproxen, phenylbutazone, ibuprofen and diclofenac.
[0025] Health regulations in various countries generally require that ophthalmic preparations shall include a preservative. Many well known preservatives that have been used in ophthalmic preparations of the prior art, however, cannot be used in the preparations of the invention, since those preservatives may no longer be considered safe for ocular use, or may interact with the surfactant employed in the suspension to form a complex that reduces the bactericidal activity of the preservative.
[0026] The preservatives of component (F) employed in the suspensions of the invention therefore are chosen to not interact with the surface active agent to an extent that the preservatives are prevented from protecting the suspension from microbiological contamination. In a preferred embodiment benzalkonium chloride may be employed as a safe preservative, most preferably benzalkonium chloride with EDTA. Other possible preservatives include but are not limited to benzyl alcohol, methyl parabens, propyl parabens, thimerosal, chlorbutanol and benzethonium chlorides. Typically such preservatives are employed at a level of from 0.001% to 1.0% by weight. Preferably, a preservative (or combination of preservatives) that will impart standard antimicrobial activity to the suspension and protect against oxidation of components (A)-(E) is employed.
[0027] In forming compositions for topical administration, the mixtures are preferably formulated as 0.01 to 2.0 percent by weight solutions in water at a pH of 4.5 to 8.0 (figures relate to combined presence of loteprednol etabonate and tobramycin). While the precise regimen is left to the discretion of the clinician, it is recommended that the resulting solution be topically applied by placing one drop in each eye two times a day.
[0028] A bioavailability study of LE-tobramycin vs. LOTEMAX loteprednol etabonate composition demonstrated that in the intend to treat population bioequivalence was met at both the 40 and 60 minute sampling periods. Thus, the inclusion of tobramycin does not alter the ocular bioavailability of loteprednol etabonate. A microbial kill rate study was undertaken to demonstrate antimicrobial equivalence between loteprednol etabonate and tobramycin ophthalmic suspension, 0.5%/0.3% and tobramycin ophthalmic solution, USP 0.3%. The methods employed were based on USP anti-microbial effectiveness procedures for preparation of inoculum and challenge concentration of test organisms. The anti-microbial activity of both products was demonstrated against 22 organisms. The in vitro study demonstrated that tobramycin has equivalent anti-microbial activity as a single agent and when in combination with loteprednol etabonate.
[0029] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments therefore are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. In the following examples, all temperatures are set forth in degrees Celsius; unless otherwise indicated, all parts and percentages are by weight.
EXAMPLES
[0030] A study was undertaken to compare a standard LE-tobramycin composition having different concentrations of Povidone and different types of Povidone. The example compositions also contained standard pharmaceutical components. Examples III and VI were used as controls (no tobramycin) to observe the effect of tobramycin on the pH of the composition. The materials were mixed with purified water and held at a temperature of 28° C. to represent room temperature stability and 40° C. to represent accelerated stability. The results are given in the tables below.
STABILITY OF LE-TOBRAMYCIN MATRIX (with different viscosity) 28° C. Time Tobra. LE (month) (mg/ml) (mg/ml) pH I 0 3.18 4.976 6.49 0.6% 1 3.076 — 6.32 PVP-C30 2 3.062 4.947 6.28 3 3.113 5.484 6.21 6 3.003 5.155 6.17 II 0 3.165 5.241 6.47 1.5% 1 3.04 — 6.3 PVP-C30 2 2.995 5.08 6.19 3 3.04 5.32 6.14 6 3.008 5.514 6.087 III 0 — 5.576 5.98 1.5% 1 — — 5.54 PVP-C30 2 — 5.411 5.06 Control 3 — 5.706 5.02 6 — 5.134 4.8 IV 0 3.206 5.296 6.71 1.5% 1 3.082 5.156 6.57 PVP-K90 2 3.122 5.29 6.49 3 3.21 5.306 6.47 6 3.146 5.358 6.39 V 0 2.802 4.32 6.61 0.5% 1 2.754 4.24 6.48 PVP-K90 2 2.596 4.28 6.38 3 2.811 4.336 6.34 6 2.806 4.365 6.32 VI 0 — 5.426 6.61 1.5% 1 — 5.638 5.033 PVP-K90 2 — 5.67 4.71 Control 3 — 5.67 4.72 6 — 5.727 4.43
[0031]
STABILITY OF LE-TOBRAMYCIN MATRIX (with different viscosity)
40° C.
Time
Tobra.
LE
(month)
(mg/ml)
(mg/ml)
pH
I
0
3.18
4.976
6.49
0.6%
1
3.15
—
6.23
PVP-C30
2
2.957
5.008
6.06
3
3.036
5.067
5.95
6
II
0
3.165
5.241
6.47
1.5%
1
3.019
—
6.21
PVP-C30
2
2.91
5.16
5.89
3
2.95
5.37
5.89
6
III
0
—
5.576
5.98
1.5%
1
—
—
4.73
PVP-C30
2
—
5.411
4.33
Control
3
—
5.473
4.11
6
—
IV
0
3.206
5.296
6.71
1.5%
1
2.94
5.336
6.47
PVP-K90
2
2.84
5.209
6.13
3
3.17
5.17
6.25
6
3.212
5.178
6.097
V
0
2.802
4.32
6.61
0.5%
1
2.588
4.284
6.38
PVP-K90
2
2.64
4.21
6.21
3
2.82
4.2
6.14
6
2.767
4.267
6.04
VI
0
—
5.426
6.61
1.5%
1
—
5.614
4.62
PVP-K90
2
—
5.91
3.93
Control
3
—
5.85
3.83
6
—
5.572
3.53
[0032] The above data represents the results of pH stability testing of various compositions having differing viscosity. PVP-C30 is Povidone having a molecular weight of around 30,000 and PVP-K90 is Povidone having a molecular weight of around 90,000. Both were obtained from the GAF Corporation, USA. In general a pH between 4.5 and 7.0 is considered acceptable for pharmaceutical ophthalmologic use of these compositions. The data demonstrates that compositions of the present invention having tobramycin display a more gradual decrease in pH over time and less of a total change in pH over time as compared to similar compositions which do not contain tobramycin.
[0033] The following example is a representative pharmaceutical composition of the invention for topical use where indicated against inflammation and infection.
EXAMPLE 1
[0000] Ingredients (per mL)
[0000]
Loteprednol etabonate 0.5% (5 mg)
Glycerin 2.5%
Povidone, K-90 0.6%
Tobramycin 0.3% (3 mg)
Benzalkonium Chloride 0.01%
Tyloxapol 0.05%
Edentate disodium 0.01%
Purified water (QS to 100%)
Sulfuric acid or sodium hydroxide (to adjust pH)
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This invention relates to formulations for topical use comprising antibiotics in combination with anti-inflammatory steroids for treating ophthalmic infections and attendant inflammation. More specifically, this invention relates to pharmaceutical ophthalmic formulations comprising a pH stabilizing amount of an aminoglycoside and a steroid in a pharmaceutically acceptable vehicle.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European Patent Application No. 10159657.5, filed Apr. 12, 2010, which is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a support element, particularly for elevators, with a support element and a drive pulley co-operating with the support element, as well as to an elevator with a corresponding support element system.
BACKGROUND
[0003] In conventional elevator installations the elevator cage and a counterweight are connected together by way of several cables or belts. The counterweight and the cage are supported and, as a rule, also moved by the cables or belts. For this purpose, drive force generated by a drive is transmitted by way of a drive pulley to the cables or belts. When the drive pulley rotates, the cable or the belt is guided over the drive pulley and thus raises or lowers the elevator cage or counterweight. In this connection, the drive moment is imposed under friction couple on the respective cable or belt section lying on the drive pulley over the looping angle.
[0004] In order to ensure a force transmission which is as efficient as possible, selection can be made of materials with a high co-efficient of friction which can be used not only on the drive pulley, but also as cable material. In addition, good guidance of the cable or belt and an efficient transmission of force are achieved by a drive pulley which follows a contour of the cable or belt so that large parts of the cable or belt surface are in contact with the drive pulley. For this purpose the surface shapes of the cable and the drive pulley have to be precisely matched to one another, since otherwise different pressures of the drive pulley on the cable of the belt occur, whereby different material loads arise in the cable or belt and therefore different levels of wear phenomena.
[0005] Moreover, in the case of different loading a uniform transmission of force to the cable or belt is not possible, so that in certain circumstances lateral forces or shear forces arise which can lead to cable torsion or cable unraveling phenomena, which in turn disrupt the cable structure in terms of its balance. Twist phenomena of that kind can occur particularly when the drive pulley or cable rollers are arranged at an angle.
[0006] A cable with two tensile carriers in an elastomeric casing is known from EP 1 061 172, wherein the elastomeric casing has an outer contour which co-operates with corresponding grooves in the drive pulley. Specifically, the cable is held by a rib, which is formed in cable longitudinal direction, in co-operation with a guide groove shape, which is provided to be complementary therewith, on the drive pulley in the track.
SUMMARY
[0007] There is therefore a need for ensuring a uniform and focused transmission of force from the drive pulley to the support element.
[0008] Accordingly, one aspect relates to a support element system, particularly for elevators, with at least one support element having exactly two load-bearing tensile carriers, which are arranged horizontally adjacent to one another and which are enclosed in a common elastomeric casing separating the two tensile carriers. The tensile carriers respectively have an opposite direction of wrap in which the maximum width and the maximum height of the cross-section of the support element have substantially a ratio of 1:1. The vertical orientation of the tensile carriers is to half the height of the cross-section of the support element, The system includes a drive pulley for transmission of a drive force to the at least one support element, wherein the drive pulley has a contoured traction surface with two support surfaces which are provided for transmission of the drive force and which co-operate with the support element.
[0009] The innovation described herein is based on the recognition that a uniform transmission of the drive force to the support element can be carried out in that the drive pulley has specific regions which are provided for the transmission of the drive force. For this purpose, the traction surface of the drive pulley is contoured so that specific surfaces arise which co-operate with the support element when it runs over the drive pulley. It is thereby achieved that the entire surface of the drive pulley does not co-operate with the support element for the force transmission, but that the force transmission takes place selectively at specific places.
[0010] The support element has a special construction for the selective transmission. The load-bearing tensile carriers, which are arranged horizontally adjacent to one another, respectively have an opposite direction of wrap. This means that the wires or fibers from which the tensile carriers are formed are twisted around in one case to the left and in the other case to the right. A torque is usually exerted on the cable by the wrap direction of a tensile carrier. Due to the fact that the tensile carriers in the support element, the torques are mutually canceling, since they are oriented against one another. When the support element runs over the support pulley, the support element is thus adjusted so that a defined surface of the support element co-operates with the surface of the drive pulley. In addition, the support element is balanced, so that the force is transmitted uniformly from the drive pulley to the two transmission surfaces.
[0011] In this connection, the tensile carriers or the cords are arranged with axial symmetry. The tensile carriers are then arranged horizontally adjacent to one another. The support element or the cable thus has a vertical axis of symmetry and a horizontal axis of symmetry. By virtue of this configuration the cable or support element is self-adjusting on the drive pulley so that it is optimally oriented with respect to the force transmission. In that regard, compensation is provided for the inherent torque of the cable and the external torque of the support pulley or of cable rollers. Overall, service life is thereby extended since the force transmission is optimized and no undesired different and thus premature abrasion takes place. In addition, it is advantageous that the cable rollers can be positioned at an angle. The support element self adjusts in its position even in the case of an angled setting of the cable rollers.
[0012] Apart from the self-adjustment it is of advantage that the cords, which are arranged horizontally adjacent to one another, are mutually supporting and thus ensure internal cable stability, which guarantees a uniform transmission of force.
[0013] The casing can be of different construction. For example, the surface can be shaped in such a manner that it forms a polygon in the cross-section of the cable. Specially formed regions, which can co-operate with the support surfaces of the traction surface, thereby arise in the support element. Ideally, the surface of the support element is so constructed that it is oriented in parallel to the support surfaces of the traction surface. In this connection, the angle in relation to the horizontal can be formed to be between 30 and 60°. The casing can be formed from an elastomeric polymer such as, for example, polyurethane or EPDM. The advantage of a surface of that kind is that a high capability of traction is imparted.
[0014] In cross-section the support element has a height/width ratio substantially of 1:1. In this embodiment, the two oppositely wrapped tensile carriers form the stabilizing horizontal axis, and profiles, for example longitudinal or transverse profiles, can be formed on the horizontal surface. The longitudinal profiles can, for example, serve the purpose of conducting away moisture and dirt. The transverse profiles ensure a lower bending stress in the support element, which overall leads to lower wear.
[0015] The coefficient of friction can also be reduced by an appropriate design of the transverse profiles. A friction element built up by way of the support pulley is interrupted by the transverse profiles, whereby overall a lower coefficient of friction arises. This has the advantage that the cable can slip over the drive pulley. At the same time, however, a high pressure which is good for traction is produced on the support element by the support surfaces. In this connection, the force is accepted by the elastomeric polymer. The polymer can have different degrees of hardness depending on which property is desired. By virtue of the transverse profiles the hardness of the polymer can be increased, since good bending can nevertheless be achieved. Overall, through variation of the cross-section of the support element and of the drive pulley and variation of the hardness of the polymer the traction capability in the entire system can be adjusted. The readiness of the support elements for discard can advantageously be determined by way of profile depth measurement of the profiles. The profiles can themselves be matched in their dimension and spacing to the drive pulley diameter. In this regard, the profiles can also be arranged alternately on the opposite sides of the cable.
[0016] The support element co-operates with the two support elements in such a manner that the forces transmitted from the drive pulley to the support element cross at the vertical axis determined by the support element itself. The vertical axis of the support element in this regard runs precisely between the two tensile carriers. The forces thus act at any point in time symmetrically on the inherently symmetrical support element, so that an optimal adjustment can take place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The various embodiments of the disclosed technology will be explained in more detail symbolically and by way of example on the basis of the figures. The figures are described conjunctively and in general, wherein:
[0018] FIG. 1 shows a support element with round cross-section and a contoured drive pulley;
[0019] FIG. 2 shows a support element with polygonal cross-section and a drive pulley;
[0020] FIG. 3 shows a support element with a surface profile oriented longitudinally;
[0021] FIG. 4 shows a support element with a surface profile oriented longitudinally; and
[0022] FIG. 5 shows a support element with a surface profile oriented transversely to the longitudinal direction.
DETAILED DESCRIPTION
[0023] FIG. 1 shows an exemplary support element 1 , which is illustrated in cross-section. The support element has two tensile carriers 11 which are surrounded by an elastomeric casing. The tensile carriers 11 are arranged horizontally in the cross-section in the support element. The two tensile carriers are separated from one another by the elastomeric material 12 . The support element has a symmetrical construction as seen in cross-section both in vertical direction and horizontal direction. The tensile carriers 11 have a wrap in opposite direction S, Z. This means that twisting of metal wires to form strands and then twisting of strands to form cords is carried out in the two tensile carriers respectively in opposite direction. If the tensile carriers are of fiber material, then the twisting is similarly in the indicated configuration. In that regard, any cable configurations with wires, strands, which are twisted to form cords are conceivable. The opposite direction of wrap S, Z has the consequence that the torques of the tensile carriers are mutually canceling.
[0024] The position of the cable is thereby stabilized when running over the support pulley and the cable or support element automatically self adjusts to the support surfaces 5 , 6 of the traction surface 4 of the drive pulley. The wires or synthetic material fibers are preferably all wrapped in parallel within a tensile carrier, thus, for example, all in S direction or all in Z direction. A maximization of the possible reverse bending during operation of the elevator is thereby achieved. For optimal orientation the cable is of symmetrical construction so that the two tensile carriers 11 are formed in such a manner that the number of wires, threads or strands used in the two cords is identical. The cable or support element 1 during running now runs over the drive pulley 2 on the two support surfaces 5 and 6 and there automatically self-adjusts in its horizontal position. The transmission of force takes place between the surface of the support element and the two support surfaces 5 and 6 . In this connection, the forces act symmetrically on the cable so that they intersect at the vertical axis of symmetry formed by the cable. A uniform and selective transmission of force from the drive pulley to the support element is thus guaranteed.
[0025] FIG. 2 shows an exemplary construction of the support element in which the support element has a polygonal shape in cross-section. The support element thereby has on the surface planar or flat regions 3 which extend over the entire length of the support element. The support on the drive pulley is thereby improved, because the drive pulley and support element co-operate over a larger region. However, this is guaranteed only when the surface of the support element is formed parallel to the surface of the drive pulley. A defined and uniform transmission of force is also made possible by the defined support surface. In that case the height h is substantially equal to the width b of the support element.
[0026] FIG. 3 similarly shows a support element which is polygonal in cross-section and which lies on a drive pulley. The support element has, at the upper side 32 and at the lower side 31 , profiles formed in longitudinal direction. These can be formed in simple manner in the elastomeric casing, for example the polyurethane, during manufacture. The profiles have the advantage that they can accept dirt and debris which in a given case stays under the support element surface. In addition, they can serve as an indicator for the wear of the support element. In this connection it is advantageous that the support element has a height/width ratio of 1:1. It is thereby possible to substantially fully utilize the width by the tensile carriers arranged in the support element and to correspondingly profile the upper and lower surface. Sufficient material is present in the elastomeric casing for formation of the profile.
[0027] FIG. 4 shows a further exemplary support element which is polygonal in cross-section. In this connection, however, the side surfaces are not formed to be of equal length, but the horizontal and vertical sides have a larger area than the diagonal side surfaces. The upper and lower surfaces have a recess which in co-operation of a guide rail 9 ensures optimal positioning of the support element on the drive pulley. In that case no force is transmitted from the guide rail to the support element. Rather, this takes place by way of the support surfaces 5 , 6 of the traction surface 4 of the drive pulley. The form of the polygonal cross-sectional shape in FIG. 4 is merely an example. Other embodiments are possible with different ratios of the horizontal to the diagonal side areas, as well as different shaping of the recesses 7 on the upper side 32 and lower side 31 of the support element.
[0028] FIG. 5 shows a further exemplary embodiment of the support element in which a polygonal cross-section was similarly selected, but in which the surfaces 32 and 31 are provided with a profile 8 oriented in transverse direction. The profile recesses can be disposed respectively opposite one another on the surfaces 31 and 32 ; they can also be formed at alternating spacing. The spacing is dependent on the size of the drive pulley. For example, four to six profile recesses of that kind are formed per drive pulley half circumference. The profiling has the advantage that the support element is more readily bendable, so that for the same bending capability a higher degree of hardness of the elastomeric material, for example of the polyurethane, can be selected. This increases service life and also improves the force transmission from the drive pulley to the support element. There is a lower degree of wear and also a lower coefficient of friction. In addition, a friction component which builds up and which arises when the support element runs over the drive pulley is interrupted. Overall, a lower coefficient of friction is thus achieved by a small friction area. This means that the cable can slip over the drive pulley. However, through the selective construction of the support surfaces the pressure able to be exerted by the drive pulley on the support element is high so that good traction is achieved. Through its special configuration the support element has a long service life and through the self-adjustment can advantageously be used particularly in cable rollers which are positioned at an angle, since due to the stabilization of the position of the cable by tensile carriers, cable unraveling is prevented even in an inclined position.
[0029] Having illustrated and described the principles of the disclosed technologies, it will be apparent to those skilled in the art that the disclosed embodiments can be modified in arrangement and detail without departing from such principles. In view of the many possible embodiments to which the principles of the disclosed technologies can be applied, it should be recognized that the illustrated embodiments are only examples of the technologies and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims and their equivalents. We therefore claim as our invention all that conies within the scope and spirit of these claims.
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A support element system, particularly for elevators, has at least one support element having two load-bearing tensile carriers which are arranged horizontally adjacent to one another and which are enclosed in a common elastomeric casing separating the two tensile carriers. The tensile carriers respectively have an opposite direction of wrap. The system has a drive pulley for transmission of a drive force to the at least one support element, wherein the drive pulley has a contoured traction surface with two support surfaces, which are provided for transmission of the drive force and which co-operate with the support element.
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BACKGROUND OF THE INVENTION
This invention relates to fluid distributing valves, more particularly to such valves wherein a fluid such as water is received from a single source and is distributed through individual conduits to a plurality of utility devices. It is an object of the invention to provide an improved distribution valve and/or a system of this nature.
The invention has particular application to a system for operating a series of pop-up cleaning heads in a swimming pool environment. It will be evident however that the apparatus and system have application to other fluid distribution systems such as sprinkler systems, tank cleaning systems and the like. The examples given are by way of illustration only and are not intended to be restrictive in any way.
Valves of the nature involved in this application are known to the prior art. For example, references may be made to the U.S. Pat. Nos. 1,753,240 Howell et al, 3,405,733 Hansen, 3,472,265 Davis, 3,779,269 Gould, 4,022,239 Schwindt et al, 4,077,424 Ehret et al and 4,313,455 Donald G. Pitman.
In each of the listed patents, except Schwindt et al, the supply water and the water outlets operate from different senses and directions, thus requiring additional plumbing connections to the source to make the device serviceable. Of these patents Hansen, Gould and Ehret et al disclose valves that may be known as a flat plate valves wherein a relatively flat valve plate having a hole therein is rotated over the outlet openings so that water flows through the particular outlet where the opening appears. These valves are not plunger operated. In the Schwindt et al patent the inlet water and the outlet water flow in conduits whose sense is the same but the direction of water flow is different, this being similar to that aspect of the subject invention. In the Howell et al patent plungers are utilized to close the valve openings but mechanical levers are used for this purpose. In the Davis patent spherical balls are used to open and close the outlets. The balls are moved into and out of position by cam surfaces. In none of the prior art devices is there a separation of flow water and control water.
In the Pitman U.S. Pat. No. 4,313,455 a distributing valve for a swimming pool is provided which has a sealed self-contained body which includes all of the working parts. This self-contained body is then attached to a base plate to which the outlet pipes are attached. The inlet pipe or conduit is attached to the top of the self-contained body and thus all of the liquid that passes to the swimming pool goes through the working parts of the valves. All of the water passing through the valve needs to be strained requiring that the strainer cannot be of optimum fineness because it would involve flow restriction. Further, since the self-contained portion of the valve must be returned on occasion to the shop for servicing a pipe union must be provided at the inlet of the device so that removal is possible.
Interiorly of the Pitman device a ring gear which provides part of the mechanism for rotating the sequencing valve structure is permanently molded as part of the removable top part. This makes engagement with the ring gear by other interior operating gears rather difficult and if something happens to damage the ring gear the whole cover part or top must be replaced.
Also interiorly of the Pitman cover are a series of individual valve members, usually of an uneven number, for example, five. The valve members are spaced from a base plate through which space the water flows from the inlet to the various outlets. That is to say, all of the working parts are in the chamber defined by a base and a cover and this chamber is filled with liquid at the supply pressure. Thus during any required pressure testing the individual valve members must be removed in order to allow flow of pressure test fluid to communicate with all circuits connected to the valve.
Further in Pitman type devices, if a normally closed valve fails, it will fail closed thereby terminating all flow through the valve with the resultant increase in static pressure resulting in possible pump and system damage. Servicing usually requires replacement of the entire valve and pressure testing is conducted by a special housing with no internal devices present followed by replacement with a working valve for normal operations. The individual valves of Pitman are moved to the closed position by the application of the supply pressure to one side of a diaphragm. In this instance, the closing rate of the valve is very difficult to control because the valve is closing with the direction of fluid flow. As the valve plunger approaches the valve seat it is no longer controlled by the pilot pressure and is rapidly forced to a closed position causing water hammer. The failure of filters and other system components is common with such prior art devices. Many attempts have been made to control this by changing valve cam angles and/or disrupting the valve seat to reduce the differential between the internal high pressure of the valve body and the low pressure area of any given valve port that is closed or closing. This further results in additional operating pressure reduction.
In the operation of prior art cleaning systems such as one utilizing the U.S. Pat. No. 4,313,455 certain problems during operation are presented. For example, cleaning heads on steps or benches in the shallow end of the swimming pool may be objectionable to swimmers. Similarly the operation of heads in the floor of the pool may be objectionable when brushing because debris may be inadvertently acted upon and dispersed before manual removal is complete. The pressure in the system or, for example, at the pump is greater when the cleaning system is in operation thus reducing the system flow (filtration rate). To achieve maximum flow when cleaning is not in operation or to stop operation of the cleaning system for any of the above reasons additional valving may be required. For example, a by-pass valve from the output of the filter to the swimming pool, and a valve in the line to the distributing valve so that the distributing valve can be rendered totally inoperative.
SUMMARY OF THE INVENTION
According to the invention a three-piece rotating distributing valve is provided having, in essence, a permanent base member, a unitized valve module for easy replacement or removal for testing and which contains all of the operating parts, and a removable top which has no plumbing connections to it. The only operating part in the wall of the removable top is a specific control knob for stopping the valve in any position desired. The permanent body base or base contains no working parts or valve seats and provides a space within which the unitized valve module is received. The permanent base member contains the inlet as well as the outlets which as a practical matter may be disposed in the same direction. As even number of outlets may be provided so that one distributing valve may be utilized as a source for two other distributing valves thus making it possible to distribute water to a greater number of utilization points. The individual valve members are disposed in the valve module and the operating members for the valves are separated from the valves themselves which operate against a shut-off plate.
The space between the valve housing and the shut-off plate provides a water flow chamber or area. The supply pressure in this area tends to close the individual valves rather than to open them. The space above the unitized valve module and underneath the removable top and certain areas within the unitized valve module provide a control chamber in which only control water is received. The flow water from inlet to outlet does not enter the control chamber except as a control function. Since only a small amount of water is necessary for control purposes this water can be strained and supplied to the control chambers through relatively small areas thus enabling very fine screens to be used to strain out any grit, or the like. The certainty of operation of the valves is greatly assured. Inasmuch as the unitized valve module is easily removed and the removable top or cover replaced pressure testing may be carried out with relatively little inconvenience.
If the diaphragms operating the valves in the applicant's structure are ruptured, for example, the valves open, thus continuing flow from the inlet through outlet. There is no consequent increase in pressure within the valve control compartment under this condition. Further since the valves close against the direction of the flow, closing rate can be precisely controlled by the design of the cam which controls the application of pressure to one side of the valve diaphragm. Consequently, there is no water hammer.
The design of the inventive system and device is such that the valve sequencing operation can be stopped at any point in its cycle, so that any particular utilization device or cleaning head can be selectively operated while all others are disabled. Thus, during the times when desired the cleaning heads on steps or benches, or anywhere else, may be turned off while a selected circuit will continue to function as an inlet means to the pool. All of this can be carried out without the provision of additional valving or piping.
It is an object of the invention to provide an improved distributing valve of the nature indicated which overcomes the defects of the prior art.
It is a further object of the invention to provide an improved distributing valve of the nature indicated wherein there is a separation of flow water and control water.
It is a further object of the invention to provide an improved distributing valve of the nature indicated which is simple in form, and concept, efficient in operation, and relatively inexpensive to construct.
It is a further object of the invention to provide an improved distributing valve of the nature indicated which is simple and economical to install, easy to service, and simple to test.
Further objects and advantages of the invention will appear as the description proceeds and it is intended to cover all of such variations as are within the scope of the disclosure.
In carrying out the invention according to one form there is provided a fluid distribution valve comprising a flow chamber and a control chamber separated from each other, a fluid passage from the flow chamber to the control chamber, inlet flow means to and a series of outlet flow means from the flow chamber, a series of valve means one each being in each of the series of outlet flow means, and means controlled from the control chamber for sequentially operating the valves of the series of valves.
In carrying out the invention according to another form there is provided a fluid distribution valve comprising a base member having a fluid inlet and a series of fluid outlets therein, a valve plate having an inlet opening and a series of valve seat openings disposed on the base with corresponding openings in alignment, a series of valve members disposed adjacent the valve seat openings for closing and opening same, a piston housing member having a series of chambers corresponding to the valve members disposed on the base and spaced from the valve plate to form a flow chamber, a series of two sided pistons one each of which is disposed in each chamber of the piston housing, each of the pistons being connected to one of the valve members for operating same, a cover member disposed on the base member over the piston housing and with the piston housing defining a control chamber, first openings connecting the flow chamber and the control chamber, second openings between one side of each of the two sided pistons and the flow chamber, third openings between the other side of the two sided pistons and the control chamber, means for controlling the third openings between an open state and a closed state, an impeller in the flow chamber adjacent the inlet opening and adapted to rotate upon flow through the inlet opening, gear mechanism in the control chamber connected to the impeller, and means operated by the gear mechanism in response to rotation of the impeller for sequentially actuating the controlling means.
In carrying out the invention according to still another form there is provided a fluid distribution valve comprising a base member having an inlet port and a series of outlet ports for attachment to plumbing connections, a removable valve module member having an inlet port, a series of outlet ports and valve operating components ponents being disposed in the base member with the inlet ports and the outlet ports in registration with each other, respectively, and a non-plumbing connection cover member attached to the base member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference may be had to the accompanying drawings in which:
FIG. 1 is a sectional view, in perspective, of a swimming pool illustrating an application of the invention;
FIG. 2 is a circuit diagram illustrating the systemic use of the inventive device with two other inventive devices;
FIG. 3 is a sectional view of the inventive device illustrating the mode of operation;
FIG. 4 is an exploded view, in perspective, on a slightly smaller scale, illustrating the various parts of the inventive device;
FIG. 5 is a fragmentary sectional view on enlarged scale of the device illustrated in FIG. 3 and 4;
FIG. 6 is a sectional view taken substantially in the direction of the arrows 6--6 of FIG. 3;
FIG. 7 is a sectional view taken substantially in the direction of the arrow 7--7 of FIG. 3; and
FIG. 8 is a sectional view taken substantially in the direction of the arrows 8--8 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings there is shown a system 10 including a swimming pool 11, shown in section, a distributing valve 12 according to the invention, a pump 13 and a filter 14 which, except for the distributing valve 12 and the system of operation, are essentially well-known. The pool is shown equipped with pop-up cleaning heads or nozzles 15 connected by appropriate conduits 16 to the distributing valve 12. The pump 13 is connected to the filter 14 and the filter to the inlet of the valve 12 by appropriate piping and the pool drain 17 is connected to the pump 13 as is well understood. Other features, such as, for example, a skimmer, not shown, would of course be associated with a pool as desired and are not shown here in the interest of simplicity and as not affecting the various aspects of the invention.
In FIG. 2 a system is shown wherein a single distributing valve 12 according to the invention may be utilized to supply two additional distributing valves 18 and 19 also according to the invention so that instead of having only six outlets there are a total of twelve. So long as there is an even number of outlets from the valve 12, two additional valves 18 and 19 may be supplied and each receive the same amount of water. For this purpose three of the outlets of valve 12 are connected together and supply the inlet of valve 19 through a conduit 21 and the other three outlets of valve 12 are connected together to the inlet of valve 18 through a conduit 22. This system may be carried further by connecting each two of the outlets of valve 12 together and thus supplying three additional distributing valves. The pump 13 and the filter 14 of course are those as shown in FIG. 1 and need not be of any larger capacity in order to supply the additional valves.
In FIGS. 3 and 4 the distributing valve 12 is shown, respectively, in assembled and exploded condition and also fragmentarily in FIGS. 5, 6, 7 and 8.
Thus the distributing valve may be considered to have a distributor valve base 23, a modular piston housing 24, pistons, operating parts and valve members to be described, a ring gear 25, a valve operator 26, a gear system 27, a distributor valve cover or top 28, a pause mechanism 31, including an operating knob 32, and additional parts as will be understood, to be described.
In the invention as illustrated there are a total of six valves and therefore six valve outlet members to serve six conduits and thus six utility devices such as pop-up cleaning heads. It will be evident that other numbers of valve members may be provided without departing from the spirit of the invention.
The distributor valve base 23 is, essentially, a cylindrical member made of lightweight plastic material and is provided with a honeycomb structure to provide the needed strength and rigidity. Interiorly of the upper portion of the base 23 there is an inner cylindrical surface 33 for receiving the exterior cylindrical surface 34 of the modular piston housing 24. The inner cylindrical surface 33 terminates in a shoulder 35 upon which the valve shut-off plate 36 forming part of the piston housing structure 24 rests, the piston housing 24 being indexed with respect to the base 23 in any well known manner so that each of the valve members assumes the correct position, as will become clear. Extending radially inwardly from the shoulder 35 is a series of ribs 37 terminating in a central ring 38, or opening, which continues to the central ring or opening 39 into which the inlet conduit 41 is received. The ribs 37 together with the central ring 38, that part of the base 23 including the shoulder 35, and the partition member 42 define a series of chambers 43. The partition member 42 includes a series of openings 44 through which water will pass to join the outlet conduits 45. In the construction as shown there will be six openings 44 each of which feeds into one of six conduits 45. The number of conduits being even one valve may be used as a source for two or more other valves to provide equal distribution of water flow as already explained.
Disposed above the base 23 is the modular piston housing 24 which includes the valve shut-off plate 36 spaced from the floor 46 of the piston module by appropriate spacers 47. The diameter of the outer cylindrical surface 34 of the module 24 is such as to just fit easily within the inner cylindrical surface 33. The fit is sufficiently close that there is no significant leakage of fluid from the top surface of the module 24 to the bottom surface or vice versa. Similarly in the assembled condition the valve shut-off plate 36 rests against the shoulder 35 on the outer diameter of the base 23 and upon the upper surface of the cylindrical opening 38 as well as the upper surfaces of the ribs 37 so that no leakage takes place from the upper surface of the valve shut off plate 36 into the chambers 43.
The valve shut off plate 36 has a series of valve openings 48 therethrough, the number being six in the instance described in order to correspond to the number of openings 44 through which the outlet water flows. The valve openings 48 have chamfered valve seats 49 and a plurality of valve members 51 (51a, 51b) are provided, one for each valve seat. When the module 24 is disposed in the base 23, the parts may be indexed so that each valve 51a is disposed to cooperate with the one of the chambers 43 cooperating with the opening 44 which is connected to outlet conduit 45a, as will be understood. The valve shut off plate 36 is disposed away from the lower wall or floor 46 of the module 24 to provide a space or chamber 52 within which is disposed the impeller 53. The space 52 together with the adjacent portion of the wall 33 of the base forms a flow chamber for the valve operation in that water flows in through the inlet opening 39, impinges upon the blades of the impeller 53 and then spreads outwardly to flow through the various valve openings 48 whenever the particular valve is open as will become clear. The impeller 53 is supported by means of a shaft 54 which extends up through a shaft bearing 55 including an extending hub 56.
The impeller 53 has a central hub 57 from which extend radially curved blades 58. The water flowing inwardly as shown by the arrow A in FIGS. 3 and 5 engages the blades 58 in the direction of water flow. Thus there is little or no shear force exerted against the blades 58 by the relatively high pressure water flowing against them. After the water hits the barrier or floor 46 of the module 34 and it is directed radially outwardly the radial component of the water flow then engages the radially extending blades 58 and causes the impeller 53 to rotate.
The piston housing 24 is essentially a hollow member for lightweight construction and includes various ribs etc. for making the structure of the necessary rigidity. Six valves operating chambers 61 are provided in the piston housing. Each chamber includes a cylindrical wall 62 adjacent the bottom of which is a cylindrical lip 63 terminating in the bottom, or floor, 64 forming part of the cylindrical chambers 61. Centrally of each cylindrical chamber 61 and centrally through the bottom is a series of openings 65 through which valve stems extend, the openings 65 being of a slightly larger diameter than the shaft or stems 66 so that an opening is provided through which water can flow into the lower valve chamber 70a from the flow compartment 52 as will be more particularly described.
In each of the cylindrical chambers 61 is a cup retainer 60 which is in effect a cylindrical member having a top surface 68 and a cylindrical wall 69. The top surfaces 68 each include an opening 71 having a conical surface 71a upon which there is adapted to seat a lightweight spherical ball 72 (72a) for valve member operating purposes as will be subsequently described. The cylindrical walls 69 include the protruding lips 73 which is received in a corresponding slot 74 in the cylindrical wall 69 for holding the cup retainers 60 in the appropriate position. On top of each top surface 68 is a pair of parallel projections 75 (FIG. 7) forming lateral retainers for the balls 72.
Disposed within each chamber 61 is a flexible diaphragm 76 (76a, 76b) which is annular in contour, the outer edge 77 of which is clamped between the lower edge of the walls
69 of the cup retainers 60 and the lips 63. The inner edge 78 of the diaphragm is clamped between two retaining members 79 and 81, in effect, forming part of the valve member operating pistons.
The retaining members 79 and 81 and the valve stems 66 which are relatively rigidly attached to them include a passageway 82. Thus there is a chamber 70b above the diaphragm 76 which is in communication with the outflow area exemplified by the outlet conduits 45 through passageway 82 and with the space 83 above the piston housing 24 and underneath the cover 28 which will be termed the control chamber.
Between the walls of the cylindrical chambers 61 and extending through the longitudinal extent of the piston housing 24 are a series of passageways 84, FIGS. 4, 7 and 8. The lower terminii of these passageways are openings across which extend fine screens 85. Thus the lower surface of a screen 85 communicates with the flow chamber or compartment 52 and its upper surface through the passageway 84 communicates with the control chamber 83. The area of each screen opening 85 is relatively small, for example, about one-half square inch in area for each opening. This is relatively quite small compared to the overall flow area as exemplified by the total cross section of six outlet conduits 45. Accordingly a relatively small amount of water flows through the screen openings 85 into the control chamber 83. Consequently the screen 85 may be very fine and thus would screen out all grit and the like. Consequently the control water in the control chamber 83 is free of grit and complications in the operation of the valve are essentially avoided. This is contrary to the operation of the valves of the prior art where the flow as it enters the valve and exits the valve for the principal flow operation passes through the valve operating area. In this case any screens that are disposed therein must be relatively course in order to avoid cutting down the principal flow.
The ring gear 25 has an annular base 86 which is disposed on the upper surface of the piston housing 24. Extending upwardly from the annular base 86 is an annular gear ring 87, gear teeth 88 being on the interior surface thereof. When the ring gear 25 is disposed on the upper surface of the piston housing 24 the screw holes 89 in the annular base 86 line up with the screw holes 91 in the webs of the piston housing so that screws 92 may hold the ring gear in position as shown in the drawing. The interior surface of the gear teeth 88 provide a barrier for preventing the balls 72 from escaping or falling out.
Interiorly of the ring gear 25 is the valve operator 26 which has a central opening 93 through which the bearing support 56 is received in the assembled condition. For this purpose a cylindrical hub 95 extends downwardly from the upper surface 96 of the valve operator. Also extending downwardly from the upper surface is an operating ring 97 which includes a protuberance or operating cam 98. The outer radius of the ring 97 is such that the ring is spaced away from the balls 72 when the balls are disposed in the chamfered openings 71 as may be seen in FIG. 5 and engages the balls to push them away from the chambered opening 71 when the cam surface 98 comes opposite the balls 72 as may be visualized in FIGS. 3 and 7.
Disposed on the upper surface 96 is a series of gears 27 of which there may be any number, four being shown in this instance, the outer gear 101 engaging the teeth of the ring gear 88 and the inner gear 102 engaging the smaller gear 103 of the pause mechanism 31, the gear 103 being attached to the shaft 54 of the impeller 53. The fit of the gear 103 on the shaft 54 is such that the impeller is held in the assembled condition.
The pause gear 103 is attached to and forms part of a catch member 104 having two oppositely extending catch arms 105 and 106. Thus it may be visualized that as the impeller 53 rotates under the influence of water flowing radially outwardly in the flow chamber 52 the pause gear 103 including the catch member 104 rotates very rapidly but with very little operating torque and, through the gear train 27 (gears 101, 102 and the gears in between) it causes the valve operator 26 to rotate inasmuch as the gear 101 engages the gear teeth 88 of the ring gear. As the valve operator 26 rotates under this influence the cam member or protuberance 98 causes the balls 72 to be moved out of and into the chamfered openings 71 in succession. The pause member 31 may be detained or paused as will be subsequently described in this specification.
The cover or top member 28 is a hood shaped member having a flanged base 107 from which the hood 108 extends upwardly. The dimensions of the hood 28 are such that the operating parts as illustrated may be easily accommodated. Extending downwardly interiorly of the hood is a ring flange 109 which extends downwardly sufficiently to be adjacent the upper surface of the piston housing 24. A slight clearance may be provided between the bottom edge of the ring flange 109 and the upper surface of the piston housing 24 so that some slight adjustment of movement of the piston housing 24 may be possible under the influence of pressure inside thereof during operation.
The flange base 107 is of a dimension to overfit the upper flange 111 at the top of the base member 23. A ring gasket 112 shown disposed in a groove forming part of the upper flange 111 seals the opening of the base 23 to the top or cover 83. A depending flange 113 surrounds an appropriate surface of the upper flange 111 to assure proper interfitting of the members. A flexible U-shaped clamping ring 114 of well-known construction may be provided to hold the cover and the base together. Further disclosure of the clamping ring 114 including the arrangements for holding two ends thereof together is not believed necessary.
At the top of the cover 28 on the dome 108 is the pause control knob 32 which has a shaft like member 115 extending through the dome at the lower end of which is a detent 116. The detent 116 includes a hook 117 which is in a location to engage either of the extending arms 105 and 106 in one position of operation which may be termed the pause position. When the knob is turned to a different location the detent 116 moves to the position shown by the broken line in FIG. 6 and thus the hook 117 is out of the way of the arms 105 and 106 whereby rotation thereof is not detained.
With this description of the operating parts further description and understanding may be provided by a description of the operation of the valve structure. In the position shown in FIGS. 3, 4 and 5 the valve 51a is shown closed and the valve 51b is shown open, these positions being assumed for purposes of explanation and are exemplary. For this condition to apply the ball 72a associated with the outlet pipe conduit 45a is on the seat 71a and the ball 72b is shown away from the chamfered valve seat 71b associated with the outlet conduit 45b.
It will be assumed for purposes of explaining the operation of the valve that water pressure is being supplied through conduit 41 as shown by the arrow A in the various figures. Water flowing in the direction of arrow A impinges upon the vanes of the impeller causing it to rotate and the water flow spreads out as shown by the arrows B in these same figures. The pressure of the water supply therefore exists in the flow chamber 52 and is exerted through the passageway 67 in the chamber 70a below the diaphragms 76. This same water pressure is exerted through the screen openings 85 and the passageways 84 in the space 83 above the piston housing 34 and the operating components shown in the control chamber 83. The water pressure in the control chamber 83 is available through the chamfered valve seat 71a whenever a particular ball 72 is moved from the valve seat so that on appropriate occasions the water pressure in the control chamber 83 is applied to the upper surfaces of the diaphragm 76 and the member 79 to which it is connected. The flow necessary to operate the valves is a relatively small amount since the only volume of water needed is that necessary to fill the chambers 6b sufficiently to cause the particular diaphragm to move downwardly.
Referring to FIG. 5 the valve body 51a is shown having a particular shape although this is not specifically significant as any shape may be used. The valve body however must have a diameter of sufficient extent so as to provide a valve closing surface 118 of the same diameter as the valve or chamfered surface 119 forming a part of a valve opening 48 in the valve shut-off plate 36. The valve 51a is shown closed, indicating that the ball 72a is in the valve seat 71a thus sealing off the pressure existing in the control chamber 83 from the chamber 70b above the diaphragm 76a. The liquid in the chamber 70b has leaked away through the passageway 82 into the conduit 45a which may be connected to the swimming pool, for example, and is at a lower pressure than exists in the flow chamber 52. The pressure in the conduit 45a is of course exerted against the undersurface of the valve 51a while the pressure in the flow chamber 52 is exerted against the upper surface of valve body 51a. However the pressure in the flow compartment is exerted through the passageway 67 into the chamber 70a below diaphragm 76a. The cross sectional area of the diaphragm including the retaining member 81 is larger than the effective area of the valve member 51a. Accordingly, the pressure in the flow chamber 52 exerted through the passageway 67 causes the diaphragm operating structure to close the valve 51a against the pressure in the flow chamber 52. Water hammer is thus avoided.
Referring to FIG. 3, the valve member 51b is shown in the open position, this valve member having the same constructional features as the valve member 51a and need not be further described. The valve 51b being shown open the ball 72b is off of the chamfered opening 71b thus permitting the pressure in the control chamber or compartment 83 to be exerted through the opening 71b into the chamber 61b above the diaphragm 76b. The pressure in the chamber 61b urges the diaphragm valve operating mechanism downwardly and since this pressure is balanced against the total pressure in the chamber below the diaphragm, although the force above the diaphragm is greater by virtue of the valve stem 66 reducing the area available below the diaphragm, there is an increased force above the diaphragm tending to open the valve 51b. The pressure in the flow chamber 52 is of course exerted against the upper surface of the valve 51b and the pressure below the valve surface 51b is that in the conduit 45b corresponding to the flow pressure and thus there is an increased force causing the valve to open and it does, as shown.
It may be visualized that when the cam surface or protuberance 98 moves out of the way the small amount of flow taking place through the opening 71b causes the ball 72b to move back into the chamfered opening 71b sealing off this opening. Hence the fluid in chamber 61b leaks off through the passageway 82 into the conduit 45b, thus reducing the pressure in chamber 61b to that in conduit 45b. Hence the pressure underneath the diaphragm 76b which is the same as that existing in the flow chamber 52 causes the valve 51b to close against the force of the flow taking place as shown by the arrows C. When the valve operating member 26 moves around to the point where the cam surface 98 moves the ball 72a out of the chamfered opening 71b thereby permitting the pressure inside of the control chamber 83 to be exerted again against the upper surface of the diaphragm 76a and the associated structure, the valve 51a again opens.
This process continues as may be visualized by observing FIG. 7 so that the balls 72a, b, etc. are successively moved out of their positions thereby opening the chamfered valve seat below and permitting the valve member in that location to open and close as the cam surface 98 moves against the ball and then away from it. As may also be observed in this figure the balls 72 etc. are held, in part, in their location by the parallel upstanding members 75 and the surface containing the gear teeth 88 of the gear ring. Thus the balls do not move out of their assigned locations. The diameter of the upper surface 96 of the valve operating member is of sufficient size to prevent the balls from moving out of the top of their confinement.
It may be observed that so long as water is flowing in through conduit 41, and then moves outwardly from arrows A toward arrows B and then arrows C, one of the valve members will always be open and therefore flow will always take place. Thus, the impeller 53 will continue to rotate and through the gear mechanism 27 will cause the valve operating member 26 to continue to rotate. The cam member 98 is of sufficient circumferential extent that there will be a slight overlap between the opening and closing of successive valves because two successive ball members 72 will have been moved away from their valve seats 71 at the same time. Thus a succeeding valve ball is moved away from its seat while the preceeding valve ball is also still away from its seat. Two valves are open at the same time. The overlap however may be as small as desired.
In the event that any of the diaphragms should rupture so that the pressure below the diaphragm and the pressure above the diaphragm become equal, the valve members 51 will open because the pressure in the flow chamber 52 is exerted downwardly against the valve members which causes them to open. If all the diaphragms should fail the valves all will remain open thereby preventing an increase in pressure in the control chamber 83 and thus on any and all of the operating components above and within the piston housing. In some prior art devices when the diaphragms fail the valves remain closed. Consequently, the pressure against the operating components becomes the same pressure that exists statically in the supply system which can damage some of the parts.
The impeller 53 rotates at relatively high speed although there is relatively little torque being exerted by it. Hence the gear system 27 is needed to convert the high speed low torque movement of the impeller at gear 102 into a relatively low speed and high torque at the gear 101. The pause mechanism 31 as has been described includes the projecting arms 105 and 106. When it is desired to stop the operation of the valve at some particular point in its rotation, for example, at the point when the valve 51b, as shown, is open, the pause control of 32 is rotated so that the detent 116 is moved counterclockwise until the hook 117 engages one of the projecting arm, for example 106. At this point the catch member 104 discontinues rotation. The shock of doing this is not great because the torque being exerted by the impeller on the pause mechanism, for example, the arms 105 and 106 is not great. When the arms 105 and 106 are no longer rotating, the gears are not rotating, the valve operating member 26 remains stationary and the particular valve 51b remains open and all other valves remain closed. This enables the particular cleaning heads, for example those on the steps as shown in FIG. 1 to remain down and not interfere with the actions of swimmers who may be using the steps to sit on. Similarly the heads 15 on the floor or on the transition areas of the floor may be stopped as desired, for example, when the pool is being manually cleaned. While the valve mechanism is stopped in one position and the valve 51b remains open the pressure inside of the control chamber 83 remains at its flow value and does not build up to the static value that exists in the supply line 41 or in the flow chamber 52 when flow is discontinued.
When it is desired again to start the valve operating so that the heads are supplied with water in succession the control knob 32 is moved to the run position which is to say that the detent 116 is moved clockwise to the position shown by the dot/dash line in FIG. 6 thus removing the hook member 117 from the arm 106. This permits the flow taking place in the flow chamber 52 to cause the impeller 53 to again rotate thereby causing the valve operating member 26 to rotate and the valves to open and close in succession.
The valve parts may be made of well-known synthetic and lightweight materials as is well understood. Other materials may of course be used.
The invention has been shown in one form. It will be understood by those skilled in the art that many variations may be made in the various parts, constructions, etc. and that it is intended by the appended claims to encompass all of the forms that come within the scope of the disclosure.
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A fluid distributing valve has the supply opening or conduit and the outlet openings or conduits disposed on the same side of the valve and oriented in the same direction. Accordingly the need for having couplings or unions to connect the supply pipe to the valve are eliminated. The valve includes a flow chamber or compartment and a control chamber or compartment so that the fluid passing through the valve does not flow past the operating members. By-passes are provided which may be finely screened to provide control water from the flow chamber to the control chamber. The valves are diaphragm operated, close, and remain closed against the flow pressure and are thus normally closed. They are open by a rotating operating cam whose operating surface moves cylindrical balls out of the way so that pressure in the control compartment can be exerted against the upper operating surface of the diaphragm operating members. A pause control mechanism is included so that the valve movement can be stopped or paused at any position desired and since in so doing the valve member at that position is open, flow continues in the flow chamber. When the pause mechanism is released the impeller begins and continues to rotate causing the distributing valve to pick up and move on from where it was stopped.
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FIELD OF THE INVENTION
[0001] The present invention relates to control valves in general and, more specifically, to a control valve with a low-noise plug and enhanced flow characteristics suited for high pressure uses.
BACKGROUND OF THE INVENTION
[0002] There are many uses for high pressure control valves, including controlling flow of gas, steam, water and the like to compensate for load disturbances and regulate process variables within a control loop. Modern high-pressure control valves use low-noise trim to enable high pressure gases and liquids to flow without excessive noise and to maintain a desired flow coefficient (Cv). Valve plugs used to modulate the flow rate under high pressure and changing pressure conditions include globe valves that use either a seat ring trim or a cage trim. A globe valve with an integral seat ring and an unbalanced valve plug is generally chosen for smaller valve sizes. In contradistinction, larger valve sizes, in order to be pressure balanced and provide for low noise, generally incorporate cage-type trim.
[0003] There are significant reasons to prefer a seat ring type trim to a cage-type trim for a control valve. For example, globe valves with a seat ring trim are lower in cost, and do not present thermal expansion problems. These valves provide better alignment of the valve plug with the valve seat and require only one gasket. Valves with seat ring trim can also incorporate a skirt that at least partially obstructs fluid flow, reducing the amount of flow in a fully open valve. In a worst case, a skirt can produce vortices, turbulence and pressure gradients causing hydrodynamic plug forces and cavitations. From the laws of fluid mechanics, it is known that when a fluid discharges from an orifice into an enlarged space a velocity head loss occurs. When pressure is reduced to vapor pressure, localized gaseous conditions occur within a liquid stream. Conversely, Bernoulli's principle provides that fluids entering a reduced area orifice from an enlarged space experience increased velocity. Thus, in a skirted valve, lowered pressure combined with skirt obstructions potentially reduces fluid flow below a desired Cv.
[0004] Known methods of addressing the problems with skirted valves include preventing or reducing erosion caused by flashing and cavitations by providing sliding stem angle valves and valves with expanded flow areas downstream of a throttling point because the erosive velocity is reduced. For those areas where the fluid must impact the valve surfaces, such as at the seating surfaces, materials are chosen that are as hard as possible. One known method of preventing cavitation in general is to control the pressure drop across the valve such that the local pressure never drops below the vapor pressure, thereby preventing vapor bubbles from forming. Without vapor bubbles to collapse, there is no cavitation. One known method of controlling the pressure drop across the valve is to split the total pressure drop across the valve using multiple stage trims. These known solutions come at the price of additional expense in further trim requirements, such as additional components and costly materials. Thus, there is a need for a control valve that provides low-noise characteristics while maintaining adequate flow rates for fluids, including gaseous fluids, which have similar noise control requirements.
SUMMARY OF THE INVENTION
[0005] A control valve is disclosed which has improved noise characteristics and control characteristics over those normally associated with cage-free control valves. The control valve has noise-reducing and flow controlling components including one or both of a slotted cylindrical skirt and a tapered metal ring that provides a fluid-tight seal between the valve housing and the metal ring. The purpose of the metal ring is to provide a low cost alternative to a conventional screwed-in seat ring and to reduce the size of the required bonnet opening.
[0006] One embodiment is directed to a control valve including a housing defining a central orifice in fluid in communication with an inlet port and an outlet port, and a movable valve plug assembly having a skirt portion slidably engaged within the central orifice to control fluid flowing through the housing. The skirt portion defines a plurality of openings which can be slots to gradually control the flow of fluid through the housing while reducing cavitation. The lower terminating end of the control valve plug incorporates concave openings.
[0007] In one embodiment, the plurality of slots have lengths that progressively increase towards the lower terminating end, and each slot expands from the outside diameter of the cylindrical skirt portion at an angle of no less than 8 degrees and no more than 30 degrees. In an embodiment, plurality of slots are configured to be at varying distances from the lower terminating end of the cylindrical skirt along the circumference to prevent steps in the rate of flow through the control valve when the valve plug is being positioned.
[0008] In a further embodiment, the control valve includes a metal ring with a tapered external surface for engaging a matching tapered bore within the valve housing. The smallest diameter of the tapered external surface at a lower terminating end of the metal ring incorporates a thinned and deformable portion capable of being pressed against a portion of the valve housing to secure the metal ring to the valve housing. In an embodiment, the taper of the external surface of the metal ring is no less than 0.5 degrees and no more than 6 degrees.
[0009] Another embodiment is directed to a valve plug capable of being slidably engaged within the central orifice of a control valve, including a top stem portion and a cylindrical skirt portion. The cylindrical skirt portion defines a plurality of slots of decreasing horizontal width relative to a lower terminating end of the cylindrical skirt portion and have varying distances from the lower terminating end.
[0010] A further embodiment is directed to a method of controlling fluid flow in a process. The method includes receiving fluids via an inlet port of a control valve, the control valve having a housing with an outlet port, a central orifice and a movable skirted valve plug, and controlling the flow of the fluid via the movable skirted valve plug within the central orifice, the skirt defining a plurality of tapered slots for controlling parameters of the fluid flow as the skirted valve plug moves within the central orifice of the control valve. In one embodiment the housing has a tapered bore for providing a seal with a metal ring that has a matched tapered external surface for engaging the tapered bore of the valve housing.
[0011] One embodiment is directed to a control valve that can, but does not require a skirted valve plug and includes a metal ring including a tapered external surface for engaging a matching tapered bore within a valve housing.
[0012] In yet another embodiment, the skirted valve plug cooperates with a conventional screwed-in seat ring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.
[0014] FIG. 1 labeled “prior art” illustrates is a cross-sectional view of a globe valve with a screwed-in seat ring and a conventional parabolic valve plug.
[0015] FIG. 2 illustrates a cross-sectional view of a skirted plug valve with a seat ring trim in accordance with an embodiment of the present invention.
[0016] FIG. 3 illustrates a cross-sectional view of a skirted valve plug with a screwed-in seat ring.
[0017] FIG. 4 illustrates a cross-sectional view of a valve plug in accordance with the present invention shown disposed with a seat ring in accordance with the present invention.
[0018] FIGS. 5 a and 5 b illustrate top views of different cross sections of the valve plug shown along the lines 5 a and 5 b in FIG. 3 in accordance with the present invention.
[0019] FIG. 6 illustrates a rolled out view of the valve plug in accordance with an embodiment of the present invention.
[0020] FIG. 7 is a graph illustrating the noise characteristics of a valve designed in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
[0021] Referring to FIG. 1 , a prior art control valve 10 is shown in a cross-sectional view. As shown, the control valve includes a bonnet 12 , a valve housing 14 having a fluid inlet 16 and a fluid outlet 18 . A connecting fluid passage 20 is defined by the interior walls of the housing 14 and is divided by a central orifice 15 . The control valve further includes a plug stem 22 with attached plug 24 . The plug stem 22 slidably engages central orifice 15 , which is used to control fluid. Control valve 10 further includes an annular valve seat or seat ring 30 , which provides a guiding and sealing surface 31 for engagement with valve plug 24 sealing surface 25 . Seat ring 30 is shown as a conventional seat ring and includes a threaded surface 33 for screwably receiving control valve housing 14 as shown. Also shown in FIG. 1 are diameter measurements D 1 and D 0 , which represent the inlet diameters through which fluids and gasses pass in the control valve 10 . The size D 0 is the central fluid passageway and will determine the flow capacity of the valve. Measurement D 1 , the external seat ring diameter, will determine the size of the top opening D of housing 14 , which is an important cost consideration.
[0022] Referring now to FIG. 2 , an improved control valve is shown. The improved skirt guided control valve 200 is designed to maintain a steady flow of liquid or other fluids through the valve. Control valve 200 includes a bonnet 212 , a valve housing 214 that defines an inlet 216 and an outlet 218 . The valve housing 214 further defines a central fluid passageway 220 . Like control valve 10 , valve 200 has a valve stem 222 . Unlike control valve 10 , however, valve 200 has a skirt guided plug 224 having leg portions 234 . Further, unlike valve 10 , valve 200 has a seat ring 230 designed in accordance with an embodiment of the present invention. Also, unlike valve 10 , control valve 200 provides components that allow for an enlarged orifice diameter D 2 compared to that of the prior art D 0 shown in FIG. 1 . Also shown in FIG. 2 is diameter D 3 , which shows the external seat ring diameter for seat ring 230 .
[0023] More specifically, referring to FIGS. 1 and 2 in combination, the difference between diameters D 0 and D 1 in FIG. 1 is substantial in comparison to the difference between diameter D 2 and D 3 shown in FIG. 2 . The differences in diameter are significant enough to provide increased flow without need for an increase in the size of opening D in housing 214 . Rather than provide an external surface for screwing the seat ring 30 to the valve housing 14 , as in control valve 10 , control valve 200 incorporates a seat ring 230 that includes a tapered portion 231 configured to engage a similarly tapered bore portion 235 within the central orifice of the valve housing 214 , as shown. In one embodiment, tapered portion 231 of seat ring 230 is thinned and deformable such that tapered portion 231 can be pressed against a portion of valve housing 214 , thereby securing the ring 230 to the valve housing. Advantageously, seat ring 230 can be used in control valves with or without skirt guiding such as skirt guiding provided by cylindrical skirted plug 224 , as described with reference to FIG. 4 , below. FIG. 2 also illustrates how skirted plug 224 mates with seat ring 230 . More specifically, rim of skirted plug 224 includes bevel 233 machined to mate with inner diameter bevel 240 of seat ring 230 .
[0024] Referring now to FIG. 3 , an enlarged detailed cross section of control valve 200 is shown to illustrate other characteristics. For example, the cylindrical skirted plug 224 is shown including a plurality of slots 340 , 342 , 344 and 346 for providing fluid egress there through. In one embodiment, the slots are varied in length to provide gradually decreasing egress area as the valve stem and plug are positioned within valve housing 214 to decrease fluid flow. Thus, as fluid flows through it, the fluid passes through successive layers of slots 340 , 342 , 344 and 346 , depending on the position of the skirted plug 224 . In its maximum open position, the fluids also pass through concave opening 364 , which will be shown and described in more detail below. These slots provide for a more gradual control of the flow of fluid through the central orifice.
[0025] The slots shown are aligned vertically and are elliptically shaped to prevent sharp edges. Although not shown, it will be appreciated by those of skill in the art with the benefit of this disclosure that the slots can also be slanted, either uniformly or nonuniformly to further alter the flow of fluids through the valve. Further, the slots are tapered, as shown with reference to openings 370 and 371 , to provide a decreased flow area through the skirt. In other words, the interior area of the slot openings nearest the center of the skirt is greater than the exterior area of the skirted plug 224 . In one embodiment, the slots are preferably tapered from the exterior area 363 of the skirted plug 224 at an angle α of between approximately 8 degrees and 30 degrees. The distance between the slots can vary depending on the preferred control characteristics that are desired. For example, the distance 390 can be approximately 0.15 inches.
[0026] The opposing slots can also be offset. For example, slot 347 can be offset vertically by approximately 0.075 inches from slots 344 and, likewise, slot 349 can be offset by approximately 0.075 inches from slot 346 . In operation, the slots prevent noise and associated problems due to changes in pressure and fluid velocity. The slotted structures serve to further disrupt the flow of fluid as it exits the valve housing.
[0027] It is known that a flow entering a small opening will develop a low static pressure causing vaporization of fluid. This vaporization leads to trap gas bubbles that subsequently collapse at a downstream location as pressures again rise, resulting in cavitation, which produce loud noises or even damage to pipes and other components. To avoid this, the liquid is accelerated from the larger cross section at concave opening 364 to the smaller cross section openings of the slots where the fluid vaporizes due to lower static pressure. The vapor is then forced to collapse adjacent to the tapered outlet of each of the slots due to higher downstream pressure. This collapse occurs before gas bubbles can aggregate into large, damaging voids further downstream. Therefore, slots 340 , 342 , 344 and 346 function to reduce noise at the outlet 218 before more significant noise problems can develop downstream.
[0028] Reference is made to the paper entitled Coefficients and Factors Relating to Aerodynamic Sound Level Generated by Throttling Valves, by Hans D. Baumann in the 1984 January-February Noise Control Engineering Journal. The contents of this paper are expressly incorporated herein by reference in its entirety for all purposes. According to this paper, it is recognized that the acoustical efficiency (in other words, noise-generating ability) will vary as a function of the degree of pressure recovery (FL factor) over a range of pressure ratios (for inlet and outlet values). Streamline passages have low FL factors and an abrupt discharge area has a high FL factor that can be close to 1.0. By providing a small cross section at the inlet and a tapered flow path toward the outlet, such as shown and described in this invention, a low FL is provided. Such a low FL is advantageous for high pressure ratios between the inlet and the outlet that are above 2:1 since this generates a lower acoustical efficiency, typically 5-10 dB over that of a high FL passage. However, when the pressure drop is low (below 2:1), a high FL is preferred for lower acoustical efficiency, typically 5-10 dB lower. In this case, the small cross section is located downstream. Hence, a range of slot sizes and configurations can be employed to custom-fit the low noise outlet section to the given pressure conditions of the valve in its normal operating range.
[0029] Referring again to FIG. 3 , depending on the configuration of the body size of a control valve, the range of slot sizes for slots 340 , 342 , 344 and 346 are variable and depend on design requirements for custom-fitting the outlet 218 to the given pressure. One embodiment for an approximately two inch body control valve calls for the smallest horizontal length 340 to be approximately 0.250 inches for an area of approximately 0.052 square inches; slot 342 to be approximately 0.58 inches for an area of approximately 0.121 square inches; slot 344 to be approximately 0.275 inches for an area of approximately 0.182 square inches; and slot 346 to be approximately 1.125 inches for an area of approximately 0.236 square inches. The distance between exterior slot openings in the vertical direction can be approximately 0.15 inches; and the exterior opening can be between approximately 0.050 and 0.055 inches wide.
[0030] Changes to these measurements can be made proportionally. With these measurements, an egress diameter of the skirted plug 224 can be approximately 1.10 inches, with a port area of approximately 1.1 square inches and a port Cv of approximately 37.4. For a control valve with body of approximately 2 inches using the slot arrangement can achieve a total Cv for the valve of approximately 45.6 with the bottom opening of the skirted plug 224 fully exposed.
[0031] FIG. 3 also illustrates an expanded view of a cross section of seat ring 230 . As shown, seat ring 230 has an off-vertical tapered lower portion 382 having an angle α 2 and an off-vertical upper portion 384 having an angle α 3 . In one embodiment, the off-vertical upper portion 384 angles inward by approximately 1.5 degrees, although other taper angles are possible, such between approximately 0.5 degrees and 6 degrees, depending on system requirements for a fluid tight press fit between the seat ring and a tapered bore 235 of the valve housing 214 . In one embodiment, as shown in more detail in FIG. 3 , the tapered portion 231 of the seat ring can be approximately at least 0.5 degrees and no more than approximately six degrees. The off vertical tapered lower portion 382 , in one embodiment, angles outward from vertical by approximately 30 degrees.
[0032] To manufacture seat ring 230 , a rolled, investment-cast or cast steel technique as known in the art can be used. To install seat ring 230 , a pressed-in steel technique can be used. More specifically, a first slight taper 235 can be machined into the central orifice of the housing bore prior to insertion of seat ring 230 . The taper matches a similar taper on seat ring 230 shown as taper 231 . After machining the bore 235 , seat ring 230 is pressed into the complimentary taper using a suitable press as is known in the art to extend seat ring from diameter D 3 to fit into tapered housing 235 . In addition, a fluid-type interface, such as an O-ring (not shown) can be placed between housing 214 and seat ring 230 to assist in sealing the housing 214 to seat ring 230 . Alternatively or in addition to using a fluid-type interface, the seat ring 230 can be locked into position by inserting a tool through diameter D 0 and rolling the taper 231 into form against the tapered portion 235 . In other words, taper 231 is deformed to lock it into position and form a permanent seal. Materials appropriate for seat ring 230 can include stainless steel, nickel alloy, stellite□ and the like.
[0033] FIG. 4 illustrates the same cross section of control valve 200 , but with a conventional screwed-in type seat ring. As shown, a control valve designed with cylindrical skirted plug 224 including slots 340 , 342 , 344 and 346 can be used with a conventional screwed-in seat ring 410 and benefit from the disclosure provided herein. With a conventional seat ring 410 , skirted plug 224 is shown with a conventional edge 420 instead of a tapered edge 233 shown in FIGS. 2 and 3 . Other geometries of tapered edges are also possible as should be appreciated by one skilled in the art.
[0034] Referring now to FIGS. 5 a and 5 b in combination with FIG. 3 , cross sections at different levels of skirted plug 224 are shown. FIG. 5 a in combination with FIG. 3 illustrates a top view cross section of the skirted plug 224 as shown at cross section horizontal 5 a in FIG. 3 . The slots provide openings 346 as shown in FIG. 5 a . FIG. 5 b illustrates a top view cross section of the skirted plug 224 between slots 346 and shows cross section horizontal 5 b at the bottom of the skirted plug 224 as shown in FIG. 3 , including openings 346 . A comparison of the cross sections at horizontals 5 a and 5 b illustrates a travel, i.e., flow through the valve, of greater than 75% when the lower recesses shown concave opening 364 of the skirt are exposed leading to a substantial increase of the flow capacity of the valve. Thus, the maximum Cv for valve 200 is increased relative to other control valves, including skirted control valves.
[0035] Referring now to FIG. 6 , the exterior surface area of the skirted plug 224 is shown as a rolled out, flattened view of skirted plug 224 to further illustrate the incorporating the slot portions 340 , 342 , 344 and 346 and concave openings 364 . In other words, FIG. 6 shows a 360° view as shown by the degree markings 0°, 180° and 360°. The view illustrates that the slot portions can be offset from one another so that as the valve opens or closes, the number of slots and portions thereof that are opened or closed at any instant in time can be reduced, thereby avoiding jumps in flow rate as more slots are exposed or removed. For example, a slight offset results in no slot being exposed conterminously with another slot, as illustrated by slots 602 and 604 . As one of skill in the art will appreciate with the benefit of this disclosure, the offset between slots is subject to design requirements. For example, an embodiment can provide that the number of slots opening at a given level be a linear function of the desired flow rates such that the steps between flow rates are minimized as limited by the number of slots.
[0036] Referring now to FIG. 7 , a graph illustrates the difference between two control valves shown in FIGS. 1 and 2 with respect to noise characteristics. The prior art control valve measurements relate to a typical two-inch control valve. The measurements are exemplary in nature showing average data for a two-inch control valve of the type shown in FIG. 1 . As is known, control valves with low-noise characteristics produce a peak frequency that typically exceeds the ring frequencies of a specific pipe. Frequencies above the ring frequency will attenuate most favorably, decaying at 6 dB per octave. FIG. 7 also provides empirical data for the improved valve described with reference to FIG. 3 having horizontal length 340 to be about 0.250 inches for an area of approximately 0.052 square inches; slot 342 to be about 0.58 for an area of approximately 0.121 square inches; slot 344 to be about 0.275 inches for an area of approximately 0.182 square inches; and slot 346 to be about 1.125 inches for an area of approximately 0.236 square inches. The exemplary two-inch control valve has a distance between exterior slot openings in the vertical direction of about 0.15 inches; and the exterior opening is approximately between 0.050 and 0.055 inches wide.
[0037] As shown, the acoustic decibels (dBA) 710 at different ratios of pressure drop versus the absolute inlet pressure (dP/PI) 700 . Line 720 provides the noise characteristic curve for known two-inch control valves using a plug configuration, such as valve 10 . Line 730 provides the noise characteristic curve for control valve 200 , incorporating the slotted skirt design. The embodiment directed to the tapered slotted skirt generates significantly lower decibels, reducing noise by up to 12 dBA for pressures from 0.1 to 0.7 dP/PI over that of a conventional plug.
[0038] While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from this invention and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention.
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A control valve that reduces noise and controls flow includes a slotted cylindrical skirt and/or a tapered metal ring. The metal ring has a tapered external surface for engaging a matching tapered bore within a valve housing. One embodiment is directed to a control valve including a housing defining a central orifice in fluid in communication with an inlet port and an outlet port, and a movable valve plug assembly having a skirt portion slidably engaged within the central orifice to control fluid flowing through the housing. The skirt portion defines a plurality of openings, which can be slots, to gradually control the flow of fluid through the housing while reducing cavitation. A method of controlling fluid flow in a process includes receiving fluids via an inlet port of a control valve, and controlling the flow of the fluid via a movable skirted valve plug with a plurality of tapered slots.
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FIELD OF THE INVENTION
The invention relates to cache memory and, more specifically to the detection of streaming data therefore to prevent the pollution of a cache and to increase the efficiency of cache memory.
BACKGROUND OF THE INVENTION
Processors and memories are key components in a computer system to perform various operations based on instructions and data given. As a processor is usually faster than its storage memory, there is a substantial amount of time while waiting for the memory to respond to a memory request. The system performance can degrade as the gap between the operating speeds of the processor and the memory increases. Fast memory is crucial to enhance the performance of computer systems, but is expensive to manufacture. A trade-off solution to this problem is to supply layers of fast local storage memory, namely cache memory, with different speeds and capacities between processors and the main storage devices.
Cache memory is built with fast memory technology. It is expensive and is usually built in small capacity relative to a main memory to save cost. A cache mirrors several segments in the main memory such that the processor can retrieve data from the cache which has faster cycle time.
In general, a cache nearer to a processor is built to perform at a faster speed and is more costly than the cache further down the memory hierarchy. The cache that is closest to a processor is called a level 1 (L1) cache. It is followed by another cache, namely a level 2 (L2) cache and the number increases as it moves down the memory hierarchy. For a cache at any level, the adjacent cache that is located closer to the processor's end is referred to as an upstream cache. A downstream cache refers to an adjacent cache that is located closer to the end of main memory side of the memory hierarchy. For example, a L1 cache is the upstream cache with respect to a L2 cache.
A cache is generally smaller than its downstream caches. During normal operations, contents in a cache will be evicted according to replacement policies to free up space for storing newly fetched data. To increase the performance of a cache, it is important to retain the data that are frequently accessed and to remove data that will not be required in the near future (e.g., data that are only required once). In some cases, the conflicts are inevitable, as the data access pattern is mostly random. On the other hand, some classes of access patterns can trigger a high miss rate depending on cache sizes, data sizes and the reusability of data.
Streaming data refers to one or more chunks of related data that, when combined, are larger than the cache size of a cache storing a portion of the data. The chunks of data can be stored either contiguously or non-contiguously in a memory space. Streaming data can be in various data structures, containing information for different types of content and applications. In most cases, these data are required only once and will be evicted without being reused. If this type of data is treated as other data in a cache, it will cause other important data to be evicted which otherwise would have stayed in the cache. When frequently used data are evicted in favor of data that will not be reused, this is an indication of cache pollution. It is unlikely for a programmer to know the configuration of all different caches located in various computer systems at the time of writing programs and hence it is impossible to tailor the programs for each system configuration to prevent cache pollution.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and is not limited by the figures of the accompanying drawings, in which like references indicate similar elements, and in which:
FIG. 1 is a simplified view of a memory hierarchy for a computer system.
FIG. 2 shows a cache, a downstream cache and an inset to a cache line in the cache.
FIG. 3 is a flow diagram of one embodiment of a process to detect potentially streaming data, driven by a downstream cache.
FIG. 4 is a flow diagram of one embodiment of a process to reclassify potentially streaming data, driven by a downstream cache.
FIG. 5 is a flow diagram of one embodiment of a process to detect potentially streaming data, driven by a target cache.
FIG. 6 is a flow diagram of one embodiment of a process to reclassify potentially streaming data, driven by a target cache.
FIG. 7 illustrates a computer system in which one embodiment of the invention may be used.
FIG. 8 illustrates a point-to-point computer system in which one embodiment of the invention may be used
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a method and apparatus for detecting and reducing cache pollution from streaming data are described. In the following description, numerous specific details are set forth. However, it is understood that embodiments may be practiced without these specific details. In other instances, well-known elements, specifications, and protocols have not been discussed in detail in order to avoid obscuring the present invention.
An embodiment of the present invention is an apparatus to detect streaming data by using additional status bit for cache lines. By detecting streaming data, the pollution of cache may be avoided. In one embodiment, the apparatus reclassifies the data if an earlier classification is not accurate or when the access pattern for the data has changed.
FIG. 1 is a simplified view of a memory hierarchy for a computer system which may be used with embodiments of the present invention. Many related components such as buses and peripherals have not been shown to avoid obscuring the invention. Referring to FIG. 1 , the memory hierarchy comprises of a processor 101 , a main memory unit 106 and several levels of cache memories 102 1 - 102 n . The processor 101 operates based on instructions and data given. These instructions and program are usually stored in hard disk and being fetched into main memory unit and then to the processor 101 when they are required. The speed of processor 101 is often faster than the speed of memory. In order to increase the efficiency of the processor 101 , cache memories 102 1 - 102 n are included between processor 101 and main memory unit 106 .
Embodiments of the invention are applicable to all the levels of cache memory or to selected levels of the caches. To facilitate the description, two levels of caches in operation are discussed. A target cache refers to the cache where detection of streaming data is intended. A group of related data is categorized as streaming data when their size is larger than the capacity of a target cache. Streaming data are often evicted before they are reused to free up space for the remaining data that did not fit in the target cache.
FIG. 2 shows a cache 201 and its downstream cache 205 . Cache 201 contains particular sections of data stored in the downstream cache 205 . Cache 201 stores a sequence of cache lines. Each cache line (e.g., 202 , 213 , 223 ) as shown in the inset is comprised of three sections, namely status bits 210 , a tag section 211 and data 212 . Data section 212 is the actual information that is stored in the cache line and can be used in the operations of computer systems. The tag section 211 contains an address tag, which is well known in the art. The status section 210 contains information (e.g., status indicators (e.g., bits)) about the current state of the data stored in the cache line, such as dirty bit, validity bit and coherence bit. In one embodiment, reuse bit 208 and S-bit 228 support the desired function of detecting potentially streaming data. Reuse bit 208 for cache line 213 is cleared (i.e., the bit value is ‘0’) when the data is first brought in to the cache. If the data is reused (accessed again) reuse bit 208 will be set (i.e., the bit value is ‘1’). In one embodiment, when a cache line is evicted and its corresponding reuse bit is clear (i.e., the bit value is ‘0’, indicating the corresponding cache line has not been used), the cache line is classified as potentially streaming data. S-bit 228 for a corresponding cache line 223 in the downstream cache will be set to indicate the data in the cache line are potentially streaming data.
In one embodiment, the cache memories include controllers 230 and 231 that manage activities in the cache memories including updating (e.g., setting, changing, clearing, etc.) the status bits. Each controller could include multiple controllers. The controllers could be located inside or outside of a cache.
Cache line 223 in downstream cache with its S-bit 228 being set indicates a cache line of potentially streaming data. It is possible that the data is not streaming data, but was evicted due to cache pollution (i.e., other data that are streaming caused the data to be evicted before they could be reused). It is also possible that the access pattern to the data will change in the future of the program execution. In this case, the data are slowly allowed to be reclassified as non-streaming data. If the data are indeed streaming data, the data will quickly be classified as streaming data again when they are evicted and reuse bit 208 being clear, with little negative effect. However, if the data are not streaming data anymore (or never were), they can be treated as non-streaming, and the target cache can take advantage of their temporal locality (to reuse again in near future).
In one embodiment, controllers (e.g., 230 and 231 ) determine if a cache line has to be reclassified based on the values of counters (e.g., 206 ). The values of counters are updated (e.g. increased, decreased, initialized) by the controllers (e.g., 230 and 231 ). Counter 206 could be associated with one or more cache lines.
FIG. 3 shows a flow diagram for one embodiment of a process to detect potentially streaming data, and classify the status of data as potentially streaming or non-streaming. The process is performed by processing logic that may comprise hardware (circuitry, dedicated logic, etc.), software (such as one that is run on a general purpose computer system or a dedicated machine), or a combination of both. In one embodiment, the processing logic is multiple controllers (e.g., controller 230 , controller 231 ).
Referring to FIG. 3 , the process begins by the processing logic determining if data in a cache line have been reused when the cache line is evicted (processing block 301 , 302 ). If data have been reused, processing logic clears the S-bit of the corresponding cache line in the downstream cache to indicate the cache line is not considered streaming data (processing block 304 ). Otherwise, classify the status of data as potentially streaming or non-streaming. If data have not been reused, processing logic determines whether the counter value associated with the cache line in the downstream cache is decreased to zero or not (processing block 303 ). If the counter value is zero, the counter is then initialized to a predetermined value and the S-bit of the cache line in the downstream cache is cleared (processing block 305 ). Otherwise, if the counter value is not zero, processing logic decreases the counter value and sets the S-bit of the cache line in the downstream cache to indicate that the cache line is potentially streaming data (processing block 306 ).
FIG. 4 shows a flow diagram for one embodiment of a process to prevent streaming data from polluting the cache. The process is performed by processing logic that may comprise hardware (circuitry, dedicated logic, etc.), software (such as one that is run on a general purpose computer system or a dedicated machine), or a combination of both. In one embodiment, the processing logic is multiple controllers (e.g., controller 230 , controller 231 ).
Referring to FIG. 4 , in one embodiment, a cache line is brought in from a downstream cache to the target cache (processing block 401 ). Processing logic checks whether the S-bit in the cache line being brought in is zero or not (processing block 402 ). If the S-bit is zero, processing logic treats the cache line as non-streaming data (processing block 404 ). Otherwise, processing logic treats the cache line as potentially streaming data (processing block 403 ).
FIG. 5 shows a flow diagram for one embodiment of a process to detect potentially streaming data. The process is performed by processing logic that may comprise hardware (circuitry, dedicated logic, etc.), software (such as one that is run on a general purpose computer system or a dedicated machine), or a combination of both. In one embodiment, the processing logic is multiple controllers (e.g., controller 230 , controller 231 ).
Referring to FIG. 5 , the process begins by processing logic determining if data in a cache line have been reused when the cache line is evicted (processing block 501 , 502 ). If data have been reused, processing logic clears the S-bit of the corresponding cache line in the downstream cache to indicate the cache line is not considered streaming data (processing block 503 ). Otherwise, if data have not been reused, processing logic sets the S-bit of the cache line in the downstream cache to indicate that the cache line is potentially streaming data (processing block 504 ).
FIG. 6 shows a flow diagram for one embodiment of a process to reclassify the status of data as potentially streaming or otherwise, and prevent streaming data from polluting the cache. The process is performed by processing logic that may comprise hardware (circuitry, dedicated logic, etc.), software (such as one that is run on a general purpose computer system or a dedicated machine), or a combination of both. In one embodiment, the processing logic is multiple controllers (e.g., controller 230 , controller 231 ).
Referring to FIG. 6 , in one embodiment, a cache line is brought in from a downstream cache to the target cache (processing block 601 ). Processing logic determines whether the S-bit in the cache line being brought in is zero or not (processing block 602 ). If the S-bit is zero, processing logic treats the cache line as non-streaming data (processing block 603 ). Otherwise, processing logic determines whether the counter value associated with the cache line in the target cache is zero or not (processing block 604 ). If the counter value is zero, processing logic initializes the counter value to a predetermined value and classifies the line as non-streaming cache (processing block 605 ). Otherwise if the counter value is not zero, processing logic decreases the counter value and classifies the line as potentially streaming data (processing block 606 ).
For the purpose of updating the counter's value to control when a cache line is to be reclassified as non-streaming data, four different policies are presented here, namely, (1) the fixed policy, (2) dynamic policy, (3) adaptive policy, and (4) the MRU information policy.
The fixed policy uses a fixed value for initialization and decreases the counter value by 1 every time either (a) a cache line is evicted from the target cache without being reused (in the first embodiment) or (b) a cache line, with its S-bit set, is brought from the downstream cache into the target cache (in the second embodiment). Basically, the counter controls the frequency of treating potentially streaming data as streaming data. A higher initialization value means data in the cache line are treated as streaming data more often than they are not. For example, if the counter is initialized to 63 (i.e., using a 6-bit counter), this allows the cache line to be reclassified as non-streaming data once for every 64 times of the event (a) or (b).
The optimal value for initializing the counter differs from application to application, and also depends on the size of the target cache. In one embodiment, processing logic uses a dynamic policy. A fixed, minimum value for initialization (for example ‘1’) is used. The value of the counter doubles every time a cache line is evicted when its reuse bit is clear, until the counter saturates. One reason for using a dynamic policy is that burst of evictions caused by streaming data should raise the bar for reclassification of data as non-streaming data.
In one embodiment, processing logic uses an adaptive policy. A second counter (known as “adaptive initial counter”) keeps track of the initialization value for the primary counter. Every time a cache line is evicted from the target cache when the reuse bit is clear, the value of the adaptive initial counter is doubled, until it saturates. Likewise, the value of the adaptive initial counter is decreased by half every time a cache line is evicted when the reuse bit is set. This policy allows the mechanism to quickly adapt to bursty behavior of both data access pattern (streaming and non-streaming).
In one embodiment, processing logic uses the MRU (most recently used) information commonly available in cache memories. For example, the target cache is a level 2 (L2) cache and the downstream cache is a level 3 (L3) cache. Assuming that a single way of the L3 cache is of size X, and the size of the L2 cache is Y. Let k be the round up integer value of the quotient of X/Y. In this case, the counter is decremented by one whenever an eviction occurs when the reuse bit of the cache line is clear and when a hit occurs in the k MRU ways of the L3 cache.
One of the advantages of detecting streaming data is that the information can be then utilized to avoid streaming data pollution in the target cache. Preventing cache pollution could help to improve the “hit” ratio of a target cache. There are multiple ways to treat potentially streaming data to achieve this goal. Three embodiments are presented here:
(1) Data treated as streaming data bypass the target cache entirely to avoid pollution by the streaming data.
(2) Data treated as streaming data are placed in the LRU (least recently used) way in the cache (assuming an LRU replacement policy).
(3) Data treated as streaming data are placed in a small buffer next to the target cache. Using an example of level 2 cache as the target cache, on a miss at the upstream cache (for example level 1), the buffer is searched in parallel to the target cache.
Embodiments of the invention may be implemented in a variety of electronic devices and logic circuits. Furthermore, devices or circuits that include embodiments of the invention may be included within a variety of computer systems. Embodiments of the invention may also be included in other computer system topologies and architectures.
FIG. 7 , for example, illustrates a front-side-bus (FSB) computer system in which one embodiment of the invention may be used. A processor 705 accesses data from a level 1 (L1) cache memory 706 , a level 2 (L2) cache memory 710 , and main memory 715 . In other embodiments of the invention, the cache memory 706 may be a multi-level cache memory comprise of an L1 cache together with other memory such as an L2 cache within a computer system memory hierarchy and cache memory 710 are the subsequent lower level cache memory such as an L3 cache or more multi-level cache. Furthermore, in other embodiments, the computer system may have the cache memory 710 as a shared cache for more than one processor core.
The processor 705 may have any number of processing cores. Other embodiments of the invention, however, may be implemented within other devices within the system or distributed throughout the system in hardware, software, or some combination thereof.
The main memory 710 may be implemented in various memory sources, such as dynamic random-access memory (DRAM), a hard disk drive (HDD) 720 , or a memory source located remotely from the computer system via network interface 730 or via wireless interface 740 containing various storage devices and technologies. The cache memory may be located either within the processor or in close proximity to the processor, such as on the processor's local bus 707 . Furthermore, the cache memory may contain relatively fast memory cells, such as a six-transistor (6T) cell, or other memory cell of approximately equal or faster access speed.
Other embodiments of the invention, however, may exist in other circuits, logic units, or devices within the system of FIG. 7 . Furthermore, in other embodiments of the invention may be distributed throughout several circuits, logic units, or devices illustrated in FIG. 7 .
Similarly, at least one embodiment may be implemented within a point-to-point computer system. FIG. 8 , for example, illustrates a computer system that is arranged in a point-to-point (PtP) configuration. In particular, FIG. 8 shows a system where processors, memory, and input/output devices are interconnected by a number of point-to-point interfaces.
The system of FIG. 8 may also include several processors, of which only two, processors 870 , 880 are shown for clarity. Processors 870 , 880 may each include a local memory controller hub (MCH) 811 , 821 to connect with memory 850 , 851 . Processors 870 , 880 may exchange data via a point-to-point (PtP) interface 853 using PtP interface circuits 812 , 822 . Processors 870 , 880 may each exchange data with a chipset 890 via individual PtP interfaces 830 , 831 using point to point interface circuits 813 , 823 , 860 , 861 . Chipset 890 may also exchange data with a high-performance graphics circuit 852 via a high-performance graphics interface 862 . Embodiments of the invention may be located within any processor having any number of processing cores, or within each of the PtP bus agents of FIG. 8 .
Other embodiments of the invention, however, may exist in other circuits, logic units, or devices within the system of FIG. 8 . Furthermore, in other embodiments of the invention may be distributed throughout several circuits, logic units, or devices illustrated in FIG. 8 .
Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that any particular embodiment shown and described by way of illustration is in no way intended to be considered limiting. Therefore, references to details of various embodiments are not intended to limit the scope of the claims which in themselves recite only those features regarded as essential to the invention.
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An apparatus to detect streaming data in memory is presented. In one embodiment the apparatus use reuse bits and S-bits status for cache lines wherein an S-bit status indicates the data in the cache line are potentially streaming data. To enhance the efficiency of a cache, different measures can be applied to make the streaming data become the next victim during a replacement.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel process for preparing novel catalysts of increased activity which comprises (1) mixing alumina with at least a Group IVB metal compound and a molybdenum compound and an aqueous solution containing at least one dissolved compound therein that imparts to said aqueous solution a pH below 6 and (2) thereafter adding to the resulting product at least one metal compound not previously added thereto.
2. Description of the Prior Art
Catalysts can be prepared that are composed of an alumina support carrying metal components thereon, for example, compounds of nickel, titanium or molybdenum.
SUMMARY OF THE INVENTION
We have found that catalysts of increased activity can be prepared by (1) mixing alumina with at least a Group IVB metal compound and a molybdenum compound and an aqueous solution containing at least one dissolved compound therein that imparts to said aqueous solution a pH below 6 and (2) thereafter adding to the resulting compound at least one metal compound not previously added thereto.
In preparing the novel catalyst herein, five separate and distinct components are required in the first stage of such preparation. The first component is alumina, which will form the support portion of the novel catalyst claimed herein. Any of the known aluminas, or any aluminum compound capable of being calcined to alumina in air at a temperature of about 200° to about 1200° C. over a period of about 0.5 to about 24 hours, can be used. When an uncalcined alumina precursor is used, it is preferably selected from any of the well-known groups of hydroxides, hydrated oxides, carbonate compounds or mixtures thereof. Examples of such compounds are pseudoboehmite, boehmite, bayerite, gibbsite, nordstrandite, and ammonium aluminum carbonate hydroxide hydrate. Of these, we prefer to employ pseudoboehmite. If a precalcined alumina is used, it can be one or more of the well-known aluminas, examples of which are gamma, eta, theta, chi, alpha, delta, iota and kappa alumina. Of these, we prefer gamma and/or eta alumina. Additionally, precursors or aluminum oxides which are non-crystalline can also be utilized. In general the alumina will have an average pore radius of about 10 to about 300 Å, preferably about 20 to about 250 Å, a surface area of about 10 to about 500 m 2 /g, preferably about 50 to about 350 m 2 /g, and a pore volume of from about 0.05 to about 2.0 cc/g, preferably about 0.10 to about 1.5 cc/g, when measured by the nitrogen adsorption method (Barrett, E. P., Joyner, L. G. and Halenda, P. P., J. Am. Chem. Soc., 73, 373 (1951)).
The second and third components required in the first stage of the claimed process are a Group IVB metal compound (or mixtures thereof) and a molybdenum compound, respectively, that are to be placed on the surface of the alumina. Any of the metal oxides of a Group IVB metal and molybdenum, or compounds of Group IVB metals or molybdenum, organic or inorganic, capable of being converted to its oxide form under the calcination conditions defined above can be used. Of these we prefer to use the corresponding metallic oxides, hydroxides or hydrated oxides and carbonates of these metals. Examples of such metal compounds are:
______________________________________TiO.sub.2, Zr(OC.sub.3 H.sub.7).sub.4,TiO.sub.2.xH.sub.2 O, Zr(O.sub.2 C.sub.5 H.sub.7).sub.4,Ti(OC.sub.3 H.sub.7).sub.4, HfO.sub.2,Ti(OC.sub.4 H.sub.9).sub.4, MoO.sub.3,Ti.sub.2 (C.sub.2 O.sub.4).sub.3.10H.sub.2 O, (NH.sub.4).sub.6 Mo.sub.7 O.sub.24.4H.sub.2 O,Ti.sub.2 O.sub.3, (NH.sub.4).sub.2 MoO.sub.4,Ti.sub.2 (SO.sub.4).sub.3, 3(NH.sub.4).sub.2.0.5MoO.sub.3.2MoO.sub.4.6H.sub.2 O,TiOSO.sub.4, [Mo(OCOCH.sub.3).sub.2 ].sub.2,ZrO.sub.2, Mo(CO).sub.6,ZrO.sub.2.xH.sub.2 O, H.sub.3 PO.sub.4.12MoO.sub.3.xH.sub.2 O,3ZrO.sub.2.CO.sub.2.H.sub.2 O, (NH.sub.4).sub.3 PO.sub.4.12MoO.sub.3.xH.sub.2 O,Zr(OH).sub.4, H.sub.4 SiO.sub.4.12MoO.sub.3.xH.sub.2 O,Zr(NO.sub.3).sub.4.5H.sub.2 O, (NH.sub.4).sub.4 SiO.sub.4.12MoO.sub.3.xH.sub.2 O, andZr(SO.sub.4).sub.2, (NH.sub.4).sub.2 Mo.sub.2 O.sub.7.______________________________________
Of these we prefer TiO 2 as the Group IVB metal compound and (NH 4 ) 6 Mo 7 O 24 .4H 2 O as the molybdenum compound.
Also required in the first stage of the process for the preparation of the novel catalyst herein is an aqueous solution containing water, as the fourth component, and dissolved therein, as the fifth component; at least one compound sufficient to impart to said aqueous solution a pH below 6, generally in the range of about 0.1 to about 5.5, but, most preferably, from about 1.0 to about 5.0. For such use any water-soluble compound, organic or inorganic, but preferably inorganic, that can impart to said aqueous solution a pH below 6 can be used. Specific examples of such water-soluble compounds that can be used include inorganic acids, such as nitric acid, sulfuric acid, hydrofluoric acid, hydrochloric acid, phosphoric acid and boric acid, organic acids, such as acetic acid, oxalic acid, citric acid, tartaric acid and formic acid, salts, such as aluminum nitrate, aluminum chloride, aluminum sulfate, ammonium nitrate, ammonium chloride and water-soluble nitrate and chloride salts of transition metals, such as iron, chromium, copper, zinc and lanthanum. Of these we prefer the mineral acids, nitric acid and hydrochloric acid. Most preferred is aqueous nitric acid having a concentration of about five to about 90 weight percent, preferably about 10 to about 70 weight percent.
If desired, for example, to further enhance the catalytic performance of the novel catalyst herein, by, for example, increasing activity, altering selectivity or prolonging useful lifetime, we can add to the mixture obtained from a combination of the above-named five components, other metal oxide(s) or metal compounds, organic or inorganic, capable of being converted to its oxide from under the calcination conditions defined above or any ammonium compound that will decompose or volatilize under the calcination conditions defined above. Thus, this can include metal compounds whose metal portions fall within Periods 4, 5 and 6 of the Periodic Table and which are selected from the groups consisting of IIA, IIIB, and IVA of the Periodic Table and the elements Mg, V, Mn, Fe, Co, Ni, Cu, Zn, Si, Sb, Bi, Cr and W. Of these we prefer to use the corresponding metallic oxides, hydroxides or hydrated oxides and carbonates as the added optional metallic component. Specific examples of such compounds include:
Group IIA metal compounds, such as:
CaO, CaCO 3 , SrO and BaO;
Group IIIB metal compounds such as:
Sc 2 O 3 , Y 2 O 3 , La 2 O 3 , Ce 2 O 3 and CeO 2 ;
Group IVA metal compounds, such as:
GeO 2 , SnO 2 and PbO;
______________________________________Other metal compounds, such as:______________________________________Cr.sub.2 O.sub.3, CoC.sub.2 O.sub.4,WO.sub.3, CoSO.sub.4,(NH.sub.4).sub.6 H.sub.2 W.sub.12 O.sub.40.xH.sub.2 O, NiO,MgO, Ni(NO.sub.3).sub.2.6H.sub.2 O,V.sub.2 O.sub.5, Ni(OH).sub.2,MnO.sub.2, NiCO.sub.3,Fe.sub.2 O.sub.3, 2NiCO.sub.3.3Ni(OH).sub.2.4H.sub.2 O,CoO, Ni(C.sub.2 H.sub.3 O.sub.2).sub.2,Co(NO.sub.3).sub.2.6H.sub.2 O, NiC.sub.2 O.sub.4.2H.sub.2 O,Co(OH).sub.2, Ni(CHO.sub.2).sub.2.2H.sub.2 O,CoCO.sub.3, NiSO.sub.4,2CoCO.sub.3.Co(OH).sub.2.H.sub.2 O, CuO,Co(C.sub.2 H.sub.3 O.sub.2).sub.2.4H.sub.2 O, ZnO,Co(C.sub.2 H.sub.3 O.sub.2).sub.3, SiO.sub.2,Co(CHO.sub.2).sub.2.2H.sub.2 O, Sb.sub.2 O.sub.3,Co.sub.2 O.sub.3.3H.sub.2 O, Bi.sub.2 O.sub.3,______________________________________
and ammonium compounds, such as ammonium hydroxide, ammonium acetate, ammonium nitrate, etc. Of these we prefer ammonium hydroxide.
The resulting mixture when the above five components are combined will contain the five components in the following amounts in weight percent:
TABLE I______________________________________ Weight Percent Most Broad Preferred Preferred Range Range Range______________________________________Alumina 15-70 20-50 25-40Group IVB Compound 0.1-25 0.5-10 1-5Molybdenum Compound 0.01-20 0.1-10 0.6-7Water 20-75 30-70 50-60Acidic Component(s) 0.001-10 0.01-2 0.1-0.7______________________________________
When the optional component is added to the above five components in the mixture, the resulting mixture will contain each of the components in the following amounts in weight percent.
TABLE II______________________________________ Weight Percent Most Broad Preferred Preferred Range Range Range______________________________________Alumina 15-70 20-50 25-40Group IVB Compound 0.1-25 0.5-10 1-5Molybdenum Compound 0.01-20 0.1-10 0.6-7Water 20-75 30-70 50-60Acidic Component(s) 0.001-10 0.01-2 0.1-0.7Optional Component(s) 0.01-20 0.1-10 0.5-5______________________________________
The mixtures defined above are preferably obtained by intimately mixing together, in any desired manner, the five or more components defined above until a substantially homogeneous entity is obtained. In an especially preferred embodiment, the alumina and the metallic component or components are first brought together and mixed, after which they are then further mixed with the aqueous solution of desired pH and then finally a combination of the molybdenum compound and optional component in a common aqueous solution are thoroughly blended with the mixture. The resulting paste, or slurry, can then be formed into any desired shape following any desired or conventional procedure to obtain extrudates or spheres, or the mixture can be spray-dried to obtain a fluid catalyst. Following this, the formed entity can be dried, for example, at a temperature of about 100° to about 200° C. to remove water therefrom, and then, optionally, calcined in air at any suitable temperature, for example, in the range of about 200° to about 1200° C., preferably from about 300° to about 800° C., for about 0.5 to about 24 hours, preferably for about two to about 20 hours.
The resulting product, composed of alumina carrying the metallic components thereon can then be treated in the second stage of the process for the purpose of adding thereon one or more catalytic components, for example, by impregnation or mix-mulling followed by, if desired and/or required, drying and calcining as defined above at the end of the first stage. The additional components that can be so added in the second stage can be one or more of the metallic components previously listed as being suitable for use in the first stage but which had not been previously used. Of these, we prefer to use nickel and/or cobalt compounds, especially nickel nitrate.
The selection of the method of additional component addition, for example, nickel nitrate or nickel carbonate, is based upon the characteristics of the added catalyst material, the nature of the desired additional component and the intended process application. For fixed-bed catalysis utilizing extrudates or other formed particles, incipient wetness (no excess solution) impregnation is the preferred procedure. The solution employed is preferably aqueous, and any combination of mutually-soluble components can be added to the catalyst by way of the solution prior to the additional drying and calcining, if used, as defined in the first stage above.
When the catalyst prepared from the five or more components has not been formed into particles, such as extrudates, then other methods of additional component blending, in addition to impregnation, can be utilized. Such methods include mix-mulling and compositing. These methods are used primarily to add insoluble components to a fluid or finely-divided catalyst. Mix-mulling implies the use of a liquid to aid in the mixing and blending of two or more solid materials. The resulting blend can be formed as described above into extrudates, spheres, etc., or additional solution can be added to form a pumpable slurry for purposes of spray drying. Compositing implies a dry mixing of two or more components. The mixture can then be formed into tablets, or a liquid can be added thereto to facilitate formation by extrusion, spheronization, etc., or a slurry can be formed to facilitate spray drying.
The addition of other components in the second stage can be done in any convenient manner, examples of which are set forth in below.
(1) Calcined extrudates can be impregnated with compounds dissolved in solution using the well-known incipient wetness (no excess solution) method. Compounds can be added in a single step wherein one or more compounds are dissolved in solution and simultaneously added to the catalyst, followed by drying and calcination. If desired, several steps can be employed with intermediate heat treatments. Thus, a procedure utilizing impregnation techniques would be to use extrudates prepared by blending alumina precursor, TiO 2 , an aqueous solution of nitric acid, and ammonium molybdate dissolved in a mixture of water and ammonium hydroxide, followed by extrusion, drying and calcination. These extrudates can then be impregnated with an aqueous solution of nickel nitrate hexahydrate, followed by drying and calcination. The resulting catalyst will contain nickel, titanium and molybdenum as oxides and alumina.
(2) The method of mix-mulling can be used when aggregates, such as extrudates, are not formed from the initial mixture. For instance, a catalyst resulting from the blending of alumina precursor, titania, an aqueous solution of nitric acid, and ammonium molybdate dissolved in a mixture of water and ammonium hydroxide can be dried, calcined and sized to 100-200 mesh particles. This catalyst can be dry blended with nickel carbonate and sufficient water to form a paste, and the resulting combination can be thoroughly mix-mulled, after which the catalyst is dried, calcined, sized to 100-200 mesh and then tabletted to obtain a catalyst containing nickel, titanium and molybdenum as oxides and alumina.
(3) A composite catalyst can be prepared by first blending alumina precursor, titania, an aqueous solution of nitric acid, and ammonium molybdate dissolved in a mixture of water and ammonium hydroxide, drying, calcining and sizing to 100-200 mesh particles. This catalysts can be blended with nickel oxide and tabletted, then dried and calcined to form a catalyst containing nickel, titanium and molybdenum as oxides and alumina.
DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE I
680.7 grams of Harshaw alumina, Al 4100P, containing 73.4 weight percent of Al 2 O 3 , and 55 grams of TiO 2 were dry mixed and the resulting mixture was further mixed with a solution consisting of 5.6 grams of 70 weight percent aqueous nitric acid that had been diluted with water to a total volume of 500 ml. The total amount of water thus present was 494 ml and the pH of the aqueous solution prior to mixing was 2.2. The components were mixed over a period of one hour to obtain a paste. The paste so obtained was further mixed with an aqueous solution containing 95.8 grams of dissolved ammonium para molybdate, 42 ml of ammonium hydroxide and 127 ml of water. The resultant mixture was then converted to 1/16" (1.6 mm) extrudates, which were then dried at 120° C. over a period of 20 hours and calcined in air at 700° C. over a period of 10 hours. A portion of these extrudates which contained 90.9 grams of Al 2 O 3 was weighed out and impregnated with a solution prepared by dissolving 17.8 grams of Ni(NO 3 ) 2 .6H 2 O in water to a total volume of 116 ml. Following impregnation the extrudates were dried at 120° C. over a period of 20 hours and then calcined at 550° C. over a period of 10 hours. The resulting catalyst was sized to 16-30 mesh. The amounts of materials used and the conditions employed are further set forth below in Table IV.
EXAMPLE II
The procedure of Example I was repeated, except that 11.1 grams of 70 weight percent aqueous nitric acid was used. The amounts of materials used and conditions employed are further set forth below in Table IV.
EXAMPLE III
The procedure of Example I was repeated except that 3.3 grams of 38 weight percent HCl was used in place of nitric acid. The amounts of materials used and conditions employed are further set forth below in Table IV.
EXAMPLE IV
The procedure of Example I was again repeated except that methyl cellulose was dry-blended with the alumina and titania. No acidic component was added to the water. The amounts of materials and conditions employed are further set forth below in Table IV.
Each of the catalysts prepared above contained three weight percent nickel metal, five weight percent titanium metal, and eight weight percent molybdenum metal present as oxides and supported on the Al 2 O 3 .
Each of the catalysts prepared above was tested for its catalytic activity as follows: In each case 102 ml of the catalyst was charged to the reactor, after which the reactor was purged with one standard cubic foot (0.028 cubic meter)/hour of nitrogen at atmospheric pressure and 149° C. for 30 minutes. The catalyst was further pretreated with a distillate, spiked with 2000 ppm of sulfur as CS 2 , which was introduced into the reactor at a flow rate of 102 ml per hour and a temperature of 149° C. Hydrogen was then introduced at a flow rate of 0.358 standard cubic feet (0.01 cubic meter) per hour and 200 psig (1379 kPa). The temperature was then raised at the rate of 26° C. per hour to 204° C. The pretreatment lasted for a period of 12 hours. After pretreatment, the distillate flow was stopped and the feedstock was begun at 204° C. and a charge rate of 61 ml per hour. The hydrogen feed rate was thereupon increased to 1.54 standard cubic feet (0.044 cubic meter) per hour and 2000 psig (13,790 kPa). Over a period of one hour the temperature was raised to 360° C. and the run was begun. The feedstock consisted of Kuwait first-stage HDS product containing 1 weight percent sulfur spiked with 1500 ppm sulfur as CS 2 . Properties of the feedstock are defined below in Table III.
TABLE III______________________________________Feedstock Properties______________________________________Gravity, °API 19.9Sulfur, Wt % 1.00V, ppm 21Ni, ppm 10Distillation, D 1160 5% over at °F. (°C.) 551 (288)10% over at °F. (°C.) 703 (373)20% over at °F. (°C.) 763 (406)30% over at °F. (°C.) 817 (436)40% over at °F. (°C.) 861 (461)50% over at °F. (°C.) 910 (488)60% over at °F. (°C.) 966 (519)70% over at °F. (°C.) 1013 (545)80% over at °F. (°C.) cracked at 70%______________________________________
The product was collected every four hours and analyzed for sulfur. The activity data obtained, presented below in Table IV, are an average for 36- and 40-hour periods. Catalyst activity was defined as follows: ##EQU1## wherein S o and S are the feedstock and product sulfur respectively.
TABLE IV______________________________________Example No. I II III IV______________________________________Initial TreatmentAl 4100P, g., 680.7 680.7 408.8 408.8TiO.sub.2,g. 55.0 55.0 33.0 33.0Nitric Acid, g. 5.6 11.1 None NoneHydrochloric Acid, g. None None 3.3 NoneMethyl Cellulose, g. None None None 3.25Ammonium Para Molybdate, g. 95.8 95.8 57.0 57.0Water, ml. 622 618 399 400Ammonium Hydroxide, ml 42 42 25 25pH of Aqueous Solution 2.2 1.6 2.2 6.4Subsequent TreatmentWt of Al.sub.2 O.sub.3 In Extrudate, g. 90.9 82.0 93.2 102Ni(NO.sub.3).sub.2.6H.sub.2 O, g., 17.8 16.1 18.3 20.1Vol. of Impregnation 116 87 135 137Solution, ml.Activity,% Hydrodesulfurization 61.6 61.0 60.4 59.6______________________________________
The unexpected advantages resulting from the process defined and claimed herein are apparent from the data in Table IV above. In each of Examples Nos. I and II wherein the pH of the aqueous solution was maintained below 6, namely 2.2 and 1.6, respectively, using nitric acid therefor, the percent hydrodesulfurization was 61.6 and 61.0, respectively. Example No. III clearly illustrates that hydrochloric acid as well as nitric acid can be used to impart a pH below 6 to the aqueous solution being used in the preparation of the catalyst. The failure to use such an aqueous solution in the preparation of the catalyst in Example No. IV resulted in a catalyst of reduced activity.
Obviously, many modifications and variations of the invention, as hereinabove set forth, can be made without departing from the spirit and scope thereof, and therefore only such limitations should be imposed as are indicated in the appended claims.
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A process for preparing novel catalysts of increased activity which comprises (1) mixing alumina with at least a Group IVB metal compound and a molybdenum compound and an aqueous solution containing at least one dissolved compound therein that imparts to said aqueous solution a pH below 6 and (2) thereafter adding to the resulting product at least one metal compound not previously added thereto.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to household appliances and, more particularly, to a combined washer and dryer that automatically moves laundry from the washer to the dryer thereby allowing the operator to avoid manually moving wet laundry and eliminating a step requiring the operator's presence. The invention includes an automatic load-feeder that automatically loads laundry into the washer.
2. Description of Related Art
Appliances for performing the tasks of washing and drying laundry are well known in the prior art and to the general public. In general, a washer (or washing machine) is used to wash laundry and a dryer is used to dry laundry. Laundry is loaded into a washer which washes the laundry using water and detergent, and then spin-drys the laundry removing most, but not all, of the water. The laundry is then manually moved to a dryer which drys the laundry by applying warm air as the laundry tumbles inside a rotating drum.
The related art teaches combinations in which a washer and dryer are bracketed together, and combinations in which a single drum is used to both wash and dry laundry. Prior art examples of bracketed washer and dryer combinations are provided by U.S. Pat. No. Des. 288,737 to Deatherage et al., U.S. Pat. No. Des. 298,873. to Erickson et al., U.S. Pat. No. Des. 374,521 to Jackovin et al., U.S. Pat. No. 3,611,756 to Brucken, and U.S. Pat. No. 4,680,948 to Rummel et al. The patents to Deatherage, Erickson, Jackovin and Brucken disclose combinations in which a washer and dryer are stacked vertically, with the dryer located above the washer, and the patent to Rummel teaches a mounting bracket assembly that facilitates the mounting of a dryer on top of a washer. The primary benefit of vertically stacked combinations is the reduction in required floor space achieved by moving the dryer above the washer. However, none of the combinations disclosed by these patents allows the operator to avoid manually moving wet laundry from a washer to a dryer, or eliminates a step requiring the operator's presence.
Additionally, U.S. Pat. No. 4,154,003 to Muller provides an example of a combination in which a single drum is used to both wash and dry laundry thereby eliminating the need to manually move wet laundry from a washer to a dryer. However, in such a combination, laundry is dried by recirculating air in the drum through a condenser which removes moisture from the air. This method of drying laundry, as the Muller patent recognizes, requires more drying time than simply discharging the moisture-laden air into the atmosphere as done by dryer-only dryers and, therefore, is a disadvantage.
Thus, none of the above mentioned patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention is a combination washer and dryer in which laundry is moved from the washer to the dryer without manual intervention thereby allowing an operator to avoid moving wet laundry and eliminating a step requiring the operator's presence. Additionally, the invention includes an automated load-feeder mounted on top of the washer which automatically drops a load of laundry into the washer. The load-feeder allows an operator to place one load of laundry in the washer and a second load in the load-feeder. After the first load has been washed and moved to the dryer, the second load is automatically dropped into the washer. The automated load-feeder thereby allows an operator to wash two loads of laundry with just one visit to the laundry room.
Accordingly, it is a principal object of the invention to allow a person to wash and dry a load of laundry without having to move wet laundry from a washer to a dryer.
It is another object of the invention to eliminate a step in the laundry cleaning process that requires a person's presence. By automatically moving laundry from the washer to the dryer, the present invention allows a person to completely wash and dry a load of laundry without having to return to the laundry room and, thereby, allows the person to leave the home during the entire washing and drying process.
It is a further object of the invention to allow a person to wash two loads of laundry with just one visit to the laundry room. With the automated load-feeder, two loads of laundry can be loaded at one time—one inside the washer and one in the load-feeder. After the first load has been washed and dropped into the dryer, the load-feeder drops the second load into the washer which then washes the second load.
Furthermore, it is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective view of a combination Washer/dryer according to the present invention.
FIG. 2 is a partially cut-away perspective view of the combination washer/dryer shown in FIG. 1 .
FIG. 3 is a perspective view of the dryer drum assembly.
FIG. 4 is a perspective view of the washer drum assembly.
FIG. 5 is a partially cut-away perspective view of the combination washer/dryer showing the washer drum inverted and the dryer drum door open.
FIG. 6 is a partially cut-away perspective view of the combination washer/dryer showing the washer drum inverted and the dryer drum door closed.
FIG. 7 is a partially cut-away perspective view of an alternative embodiment of a combination washer/dryer.
FIG. 8 is a perspective view of an alternative embodiment of t the dryer drum assembly.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of a combination washer/dryer 10 according to the present invention. It will be appreciated from the view that the washer 20 and dryer 30 are stacked vertically with the washer 20 on top and that an automatic load-feeder 40 is mounted on top of the washer door 22 . It will also be appreciated from the view that two control panels 11 and 12 are located on the front of the device 10 . The upper control panel has knobs and buttons 11 that control both-the washer 30 and the load-feeder 40 and, similarly, the lower control 12 panel has controls for the dryer 30 .
FIG. 2 shows the washer drum assembly 21 located above the dryer drum assembly, and the load-feeder 40 mounted on top of the washer door 22 (FIG. 1 ). When the load-feeder door 42 is opened, laundry falls from the hopper 41 , through an opening 43 in the washer door 22 and into the washer drum 23 . After laundry has been washed, the washer drum 23 is rotated into an inverted position (See FIG. 5) thereby allowing the laundry to fall through a chute 13 and into the dryer drum 31 . A gentle shake cycle, in which the washer drum 23 is rotated clockwise and counterclockwise in short alternating intervals, helps laundry drop from the washer drum 23 into the chute 13 . The chute 13 is tapered from top to bottom to help guide laundry into the dryer drum 31 . Laundry is removed from the dryer through the dryer door 32 which is located on the lower front portion of the device 10 .
FIG. 3 illustrates the dryer drum assembly 137 . The dryer drum 31 is cylindrical in shape with a rectangular opening 34 on its side. One end of the dryer drum 31 has a round opening 39 through which laundry can be inserted into or remove from the dryer drum 31 . The round opening lines up with the dryer door 32 (See FIG. 2 ). The other end of the dryer drum 31 , which is open, mates to an inner wall 136 of the device 10 . Warm air is vented into the drum 31 through the wall 136 and moisture-laden air is removed from the drum 31 via a filtered vent 36 located below the dryer door 32 (See FIG. 2 ). A hose 37 carries the moisture-laden air from the filtered vent 36 to the rear of the device 10 .
The dryer drum 31 rests on two bearing blocks 38 each with a plurality of bearings 138 . One of the bearing blocks 38 supports the front end of the dryer drum 31 and the other (not shown) supports the rear end. The dryer drum spins freely on the bearings 138 and is rotated by a belt 139 driven by a motor 33 mounted to the frame of the device 10 .
To retain laundry in the dryer drum 31 while the dryer drum is rotating, a concave dryer drum door 35 covers the rectangular opening 34 . The dryer drum door 35 rotates partially around the drum 32 to uncover the opening 34 and allow laundry to drop into the dryer drum 31 from the washer drum 23 . The dryer drum door 35 is mounted on a track and is opened and closed by two gear assemblies 131 , one of which is driven by a gear motor 132 mounted on the outside of the dryer drum 31 . When the rectangular opening 34 is positioned under the washer drum 23 , a retractable electrical contact 135 provides power to the gear motor 132 via a conduit 134 .
FIG. 4 shows the washer drum assembly 21 . The washer drum 23 is cylindrical in shape with a closed bottom and an open top. The drum 23 is comprised of a water-tight outer drum 124 and a perforated inner drum 123 . An agitating arm 29 is mounted inside the drum. The agitating arm 29 is rotated clockwise and counter-clockwise by a motor 28 and belt 27 assembly, of which the motor 28 is attached to the bottom of the drum 23 . One end of a bearing/axle assembly 24 is attached to opposite sides of the drum. The other end of each bearing/axle assembly 24 is mounted to the frame of the device 10 . A belt 26 driven by a motor 25 rotates the axle portion 126 of one of the bearing/axle assemblies 24 thereby inverting the drum 23 .
A chute 13 is positioned below the washer drum 23 to guide laundry into the dryer drum as the laundry falls from the washer drum 23 . The chute 13 is rectangular in shape with sides that taper inward from top to bottom.
The washer drum 23 has a water supply hose 122 which fills the drum 23 with water, and a drain hose 121 through which water is drained from the drum 23 after each wash or rinse cycle.
FIG. 5 shows the washer drum 23 inverted and the dryer drum door 35 open. When inverted, the washer drum 23 drops washed laundry through the chute 13 and into the dryer drum 31 .
To receive laundry from the washer drum 23 , the dryer drum 31 is positioned with its opening 34 under the chute 13 and with its door 35 in the open position.
The load-feeder 40 is mounted on top of the washer door 22 . The load-feeder door 42 is on a track and is opened and closed by two gear assemblies 44 one of which is driven by motor 45 mounted on the washer door 22 . When the load-feeder door 42 is opened laundry drops from the load-feeder hopper 41 through the opening in the washer door 43 and into the washer drum 23 (See FIG. 2 ).
FIG. 6 shows the washer drum 23 inverted and the dryer drum door 35 closed. FIG. 6 is identical to FIG. 5 except that the dryer drum door 35 is closed.
FIG. 7 depicts an alternative embodiment of a combination washer/dryer. The alternative embodiment 80 differs from the preferred embodiment in that the dryer drum assembly 61 , described in detail below, runs from side to side as opposed to front to back.
FIG. 8 shows an alternative embodiment of the dryer drum assembly 61 . The dryer drum 62 is cylindrical in shape with two closed ends and a rectangular opening 64 on its side. One end of a bored bearing/axle assembly 65 is attached to each end of the drum 62 such that the bores open into the dryer drum 62 . The other end of each bearing/axle assembly 65 is mounted to the frame of the device 80 via a mounting plate 165 (shown on only one of the bearing/axle assemblies) thereby supporting the drum and allowing it to rotate freely. A belt 67 driven by a motor 66 rotates the axle portion 68 of one of the bearing/axle assemblies 65 , thereby rotating the dryer drum 62 . The motor 66 is also mounted to the frame of the device 80 . Similar to that of a conventional dryer, the dryer drum 62 rotates on a horizontal axis. However, unlike a conventional dryer, the dryer drum 32 rotates from front to back as opposed to side to side.
A concave dryer drum door 63 covers the opening 64 in the drum 62 to retain laundry while drying. The drum door 63 rotates partially around the drum 62 to uncover the opening 64 and allows laundry to be dropped into and removed from the drum 62 . The dryer drum door 35 is mounted to the bearing/axles assemblies 65 via sleeves that ride on the axles. A motor 69 , mounted on one end of the drum 62 , drives a belt 161 that rotates one of the sleeves thereby rotating the sliding door 63 into either an open or closed position.
Warm air is supplied to the dryer drum 62 via a hose 162 attached to the distal opening in one of the bored bearing/axle assemblies 65 . Moisture-laden air is removed from the dryer drum 62 via a second hose 164 attached to the distal opening of the other bored bearing/axle assembly. Moisture-laden air passes through an air filter 163 before as it is removed from the dryer drum 62 .
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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A combined washer and dryer that automatically moves laundry from the washer to the dryer thereby allowing the operator to avoid manually moving wet laundry and eliminating a step requiring the operator's presence. The invention includes an automatic load-feeder that automatically loads laundry into the washer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/390,369, entitled “Integrated Fiber Cement and Foam as Insulated Cladding with Enhancements,” filed Oct. 2, 2014, now U.S. Pat. No. 9,260,864, which is a national phase entry of PCT Application Number PCT/US13/35033, filed Apr. 2, 2013, which claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/619,872, filed on Apr. 3, 2012. Each of the applications referenced in this paragraph is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present disclosure generally relates to building construction materials and methods, and more particularly relates to composite fiber cement cladding with improved properties and methods of installing such material.
Description of the Related Art
The future of building construction is moving towards providing an insulated, energy efficient building envelope. In particular, there is an increasing demand for energy efficient residential and commercial constructions which require walls having greater building insulation ratings. The R-value of building insulation is a measure of its resistance to transferring heat or thermal energy. Greater R-values indicate more effective building insulation. The higher the R-value of the insulation of a building, the easier it is to maintain a temperature differential between the interior and the exterior of the building over an extended period of time. One approach to improving the energy efficiency of a building structure is to add insulation to the exterior walls. Adding additional wall insulation, however, can drive up the cost of construction as it requires additional material and installation labor. Adding additional exterior wall insulation can adversely affect the aesthetics, water management, and other properties of the wall structure assembly, as well as impact the design of other components of the wall.
Foamed material is one type of material that can be used to insulate building structures. While foamed material has been used as an insulation material in certain building construction, it has not been used as efficiently and effectively as it could be. For example, foam sheathing or backing boards have been placed between the framing and fiber cement exterior sidings of a building structure to provide additional insulation. The foam sheathing or backing boards are typically tacked or fastened to the framing prior to installation of the exterior cladding. To reduce the amount of air exchanged between the inside and the outside of the building structure, the seams of the foam sheathing or backing boards often need to be sealed or taped. As such, the installation of the foam sheathing requires additional processing steps. The foam installation may also create aesthetic issues with the exterior siding, such as causing a wavy appearance as when siding is installed over deformations in the foam where fasteners compress the underlying foam.
Additionally, in high-wind regions, sidings are frequently blown off walls of building structures. To improve wind resistance, shims are often used to create a uniform and flat surface for attachment of the sidings so as to reduce gaps that could catch the wind. Face nailing instead of blind nailing is also recommended, particularly for fiber cement sidings in regions with high wind speed. However, these existing methods for enhancing wind resistance of sidings require additional material and labor, and can detract from the aesthetics of exterior building structure.
In view of the foregoing, there is a need for a different building construction material and technique for improving the insulation of building structures and improving the wind resistance of exterior sidings. There is also a need for an improved fiber cement composite insulation building material designed without the shortcomings of existing site assembled systems that incorporate foam as an insulating material.
SUMMARY OF THE INVENTION
Accordingly, disclosed herein are integrated fiber cement and foam cladding systems that incorporate foam or similar light weight material, such as lightweight mats of fiberglass or rockwool, for improving the insulation capacity of a cladding material. In various embodiments, the integrated fiber cement and foam cladding system is designed to improve existing uses of foam and fiber cement during the construction of a wall or other structure in one or more of the following areas: reduced installation time, increase wind loads, simplified assembly, nail holding ability, resistance to thermal bridging, water management, and transportation. As used herein, the terms “foam” or “foamed material” are broad terms and shall have their ordinary meaning and shall include, but not be limited to polymeric foams, inorganic foams, cementitious foams, glass foams, ceramic foams, metallic foams, aerogels, syntactic foams and the like in a substantially solid state.
In one application, the integrated fiber cement and foam system of the present disclosure is prefabricated and designed with a structure that has sufficient integrity to sustain its connection with the building frame under high wind loads.
Accordingly, in one embodiment of the invention, there is provided a prefabricated integrated fiber cement and foam insulation panel comprising: a fiber cement layer having a front side and a back side spaced apart to define an intermediate portion and an edge member extending around the intermediate portion; a foam layer having a front side and a back side spaced apart to define an intermediate portion and an edge member extending around the intermediate portion; and an adhesive layer disposed between the fiber cement layer and the foam layer, said adhesive layer adapted to attach the fiber cement layer to the foam layer.
In a further embodiment of the invention, the foam layer is configured to facilitate alignment and assembly of multiple panels together. In one implementation, the foam layer is profiled with an interlocking feature such that adjacent foam layers will interlock when the siding panels are installed. This interlocking feature facilitates alignment of the siding panels, inhibits the infiltration of air and water between the panels and also increases wind loads on the structure by improving the resistance of the panels to the effects of strong winds impinging on the wall.
Accordingly, in a further embodiment of the invention, there is provided an exterior cladding system for building structures. The system comprises a first panel and a second panel, wherein each panel comprises a fiber cement layer and a foam layer, the fiber cement layer of each panel being secured to the respective foam layer, the foam layer of each panel comprises interlocking means. In one embodiment of the invention the interlocking means comprises a receiving channel or mating channel whereby the receiving channel or mating channel of the foam layer of the first panel engages with the receiving channel or mating channel of the foam layer of the second panel when the first and second panel are placed in a contiguous arrangement such that at least a portion of the receiving or mating channel of each of the foam layers abut in an interlocking arrangement.
In a further embodiment of the invention the fibre cement layer is secured to the foam layer by means of an adhesive layer. It is to be understood that any other suitable type of securing means known to a person skilled in the art could also be used. Preferably the method of securing the fibre cement layer to the foam layer allows for thermal, cyclic differential expansion between the fibre cement layer and the foam layer and or any other layers which may be present.
Accordingly, in a further embodiment of the invention, there is provided an exterior cladding system for building structures. The system comprises a first panel and a second panel, wherein each panel comprises a fiber cement layer and a foam layer, wherein the fiber cement layer of each panel is pre-attached to the respective foam layer by an adhesive selected to accommodate the stresses generated by cyclic differential expansion between the fiber cement layer and the foam layer, wherein the foam layer of the first panel comprises an elongate mating channel defined by two opposing sidewalls formed along a longitudinal edge of the foam layer of the first panel, wherein, the foam layer of the second panel comprises an elongate protrusion formed along a longitudinal edge of the foam layer of the second panel, the protrusion on the foam layer of the second panel being configured to be received into the mating channel on the foam layer of the first panel in a manner such that the sidewalls formed on the foam layer of the first panel enclose the protrusion formed on the foam layer of the second panel in a manner such that the foam layer of the first and second panels interlock.
In a further embodiment of the invention, the fiber cement layer is configured to facilitate alignment and assembly of multiple panels together. In one implementation, the fiber cement layer is profiled with an interlocking feature such that adjacent fiber cement layers will interlock when the siding panels are installed. It is to be understood that in other embodiments of the invention the foam layer of the exterior cladding system can be configured such that the interlocking means is located on any two opposing edges of the foam layer. In an alternative embodiment of the invention the interlocking means can be located on at least two opposing edges of the foam layer.
Conveniently in a further embodiment of the invention, the foam layer comprises an interlocking feature extending around at least a portion of the edge member to facilitate alignment and assembly of the multiple panels together. In a further embodiment of the invention, the interlocking feature is configured to improve the wind load of the installed prefabricated integrated fiber cement and foam insulation panel. In one embodiment of the invention, the interlocking feature comprises complementary shaped tongue or groove configurations. In a further embodiment of the invention, the foam layer is configured to interlock with adjacent foam layers in a manner such that the integrated fiber cement and foam insulation panels are arranged in a nested configuration.
In yet another application, the integrated fiber cement and foam system provides foam backed siding planks that provide the functional equivalent of continuous insulation and a thermal break across the framing members. In yet another embodiment, the integrated fiber cement and foam system is configured to form a substantial air seal between the individual components of the system. In yet another arrangement, the integrated fiber cement and foam system provides a foamed back lap or panel siding that allows the installer the flexibility to adjust the joints between individual laps or panels and yet maintain a sealed air barrier. In yet another application, the integrated fiber cement and foam system is designed to aid in the placement of fasteners.
In yet another arrangement, the integrated fiber cement and foam system is designed with a continuous, uninterrupted drainage plane and can prevent water from being trapped between the foam layer and wall sheathing which normally surrounds the structural support of the building structure. In one embodiment of the invention, either the foam layer or the fiber cement layer is configured with one or more drainage channels to provide a drainage plane. In other implementations, drainage channels are formed either on the interior or exterior surface of the foam layer or within the foam layer itself for effective water management within the wall cavities. In a further embodiment of the invention, a plurality of drainage channels are formed in the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed on at least one of the surfaces of the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed inside the foam layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed on at least one of the surfaces of the fiber cement layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention, a plurality of drainage channels are formed inside the fiber cement layer of the integrated fiber cement and foam insulation panel. In a further embodiment of the invention the integrated fiber cement and foam insulation panel, at least one surface of the foam layer is provided with a pattern which provides a series of drainage channels in the integrated fiber cement and foam insulation panel. The pattern can adopt any suitable form, for example, a Chevron pattern or a plurality of repeating emblems or logos. In a further embodiment of the invention the foam layer is porous. Conveniently, the foam layer is sufficiently porous to permit water drainage.
In a further embodiment of the invention, the integrated fiber cement and foam insulation panel comprises a fiber cement layer and a foam layer, wherein the width of the foam layer is smaller than the width of the fiber cement panel so as to form an overhang on the integrated fiber cement and foam insulation panel.
In a further embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises a reinforcement mesh layer. In one embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises a reinforcement mesh layer embedded in said foam layer. In a further embodiment of the invention, the integrated fiber cement layer and foam insulation panel further comprises a reinforcement mesh layer intermediate the fiber cement layer and the foam insulation layer. In a further embodiment of the invention, the integrated fiber cement layer and foam insulation panel further comprises a reinforcement mesh layer embedded in the fiber cement layer, intermediate the fibre cement layer and the foam insulation layer. In a further embodiment of the invention, the integrated fiber cement and foam insulation panel further comprises one or more fastening tabs. In a further embodiment, the one or more fastening tabs are disposed between the foam layer and the fiber cement layer. In another embodiment, the one or more fastening tabs are disposed on and/or adjacent to the back side of the foam layer. In a further embodiment, the one or more fastening tabs are attached to the panel in a manner such that a portion of each tab extends outwardly from the lateral edges of the foam layer.
In an embodiment, a method of installing integrated fiber cement and foam insulation panels on a building structure having a framing comprises the steps of: installing one or more starter strips at the base of a wall of the building to form a plank angle; and installing the fiber cement and foam insulation panels sequentially up the wall. In an embodiment, the method further comprises the steps of crotchedly vertically nesting the fiber cement and foam insulation panels. In an embodiment, the method further comprises the steps of installing an insert behind a butt joint intersection between adjacent fiber cement and foam insulation panels; wherein the insert comprises a foam layer with the same profile as a foam layer in the fiber cement and foam insulation panels as a flashing layer. In a further embodiment, wherein the fiber cement and foam insulation panel comprises one or more fastening tabs, the method further comprises the steps of installing the panels to the framing by attaching the one or more fastening tabs to the framing, wherein the fastening tabs are attached to the fiber cement and foam insulation panels in such a manner that at least a portion of each fastening tab is concealed from view when the panels are installed on the building structure.
In yet another application, the integrated fiber cement and foam system is configured to be stacked in a manner during transit so as to reduce damage normally sustained by foam materials while in transit.
In some embodiments, the integrated fiber cement and foam insulation system comprises a prefabricated fiber cement and foam insulation siding panel. The prefabricated panel includes a fiber cement layer and a foam layer attached thereto, preferably by an adhesive. The fiber cement layer can be a panel, a plank, a shingle, a strip, a trim board, or the like. In a further embodiment of the invention the fiber cement and foam insulation siding panel comprises an oriented strand board (OSB), said OSB is attached to the foam layer on the opposing side of the fiber cement layer. Various embodiments of the integrated fiber cement and foam insulation system will be described in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1B illustrate an integrated fiber cement foam and insulation siding panel according to one embodiment of the present disclosure.
FIGS. 2A-2C illustrate an integrated fiber cement foam and insulation siding panel according to another embodiment of the present disclosure.
FIGS. 3A-3I illustrate embodiments of foam layer profiles that can be incorporated in an integrated fiber cement and foam insulation panel.
FIGS. 3J-3N illustrate profiles of foam starter strips of various embodiments.
FIG. 4A-4D illustrates an embodiment of integrated fiber cement and foam insulation panels incorporating drainage features of various embodiments.
FIG. 5 illustrates an integrated wall assembly according one embodiment of the present disclosure.
FIG. 6A-6I illustrate various embodiments of an integrated fiber cement and foam insulation panel with integrated fastening tabs.
FIG. 7 illustrates yet another embodiment of the present disclosure showing a prefabricated integrated fiber cement and foam insulation panel with a backing disposed on the backside of the foam layer.
FIG. 8 illustrates yet another embodiment of the present disclosure showing an integrated fiber cement and foam insulation system that incorporates a discontinuous layer in the foam backing for acoustic dampening purposes.
FIG. 9 illustrates an embodiment of the present disclosure showing a fiber cement and foam insulation panel designed for high shear applications.
FIGS. 10A-10C illustrate embodiments showing two fiber cement and foam insulation panels joined together with a butt joint.
FIGS. 11A and 11B illustrate certain connection mechanisms that can be used to join adjacent integrated fiber cement and foam panels at a butt joint.
FIG. 12 depicts a flow diagram of installation of fiber cement and foam insulation plants according to one embodiment.
FIG. 13 depicts yet another embodiment of an integrated fiber cement and foam insulation panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
References will now be made to the drawings wherein like numerals refer to like parts throughout. FIG. 1A illustrates an integrated fiber cement and foam insulation panel 100 configured for exterior siding applications in accordance with various embodiments of the present disclosure. The panel 100 generally includes a fiber cement layer 102 and a profiled foam layer 104 attached thereto. The fiber cement layer 102 can be in the form of a plank, a siding, a shingle, a strip, a trim board, or various other building components. In a preferred embodiment, the fiber cement layer 102 is configured as a siding used for exterior wall applications. The profiled foam layer 104 can be made of open-celled and/or closed-celled foam or other similar lightweight material with insulating material properties, such as polystyrene foam, mineral based foams, foamed cement or gypsum, phenolic foams, and aerogels. Additionally or alternatively, the profiled foam layer 104 may also comprise mineral fibers or fiberglass, cellulose, polyisocyanurate, polystyrene, polyurethane, cotton fibers, and mineral wool. The profiled foam layer 104 may also include as part of its formulation water repellent agents, fire retarding agents, termiticides, insecticides or repellents, gases that enhance R-value retention, fillers that enhance R-value and the like. In some embodiments, the profiled foam layer 104 may be a composite foam comprised of materials with differential composition, density, compressive strength or fastener holding ability. As shown in FIG. 1A , the profiled foam layer 104 is adhered to an interior surface or backside 105 of the fiber cement layer 102 and extend substantially across the length of the fiber cement layer 102 such that the profiled foam layer can provide continuous insulation and thermal break across between the fiber cement layer and framing members upon installation of the panel 100 . Preferably, the profiled foam layer 104 extends partially across the width of the fiber cement layer 102 so as to leave an overhang portion 108 . The overhang portion 108 is adapted to overlap with adjacent panels when the panels are installed in a nesting configuration. In other embodiments, the profiled foam layer 104 does not extend across the entire length of the fiber cement layer 102 so as to accommodate possible expansion of the foam due to thermal effects upon installation of the panel 100 .
In various embodiments, a specially formulated adhesive layer 106 is uniformly disposed between the interior surface 105 of the fiber cement layer 102 and the profiled foam layer 104 to form a strong and uniform bond between the foam and the fiber cement across the entire panel 100 . The adhesive layer 106 is preferably formulated to establish an effective chemical and/or mechanical interlocking bond with both the foam and the fiber cement. In one embodiment, the adhesive layer 106 may be made of polyurethane, poly urea or isocyanate based materials. Preferably, the adhesive layer when bonding styrene foam to fiber cement is a high-shear strength adhesive that will not attack or eat away at either the fiber cement or styrene foam. Preferably, the adhesive layer will offer a durable bond between the fiber cement and foam layers in a variety of environmental condition including cold and warm conditions, dry and wet conditions, and freeze-thaw conditions, with salt, and in alkaline solutions, etc. The adhesive layer also preferably maintains its adhesive properties through exposure to many cycles of temperature swings (hot to cold), moisture conditions (wet to dry), and/or freeze-thaw cycles.
In one embodiment, the adhesive layer can be made of a water based adhesive, solvent based adhesive, and 100% solid. The adhesive layer can be formed in a liquid form, in, a paste form, and/or in a solid form as hot melt adhesive. The chemistries can include one and two component polyurethane, one and two part epoxy, polyvinyl acetate, polyolefin, amorphous polyolefin, pressure sensitive polyolefin, poly ethylene vinyl acetate, and/or polyamide. In some embodiments, the adhesive may be a hot melt or reactive hot melt adhesive. In such embodiments, it is preferable that the hot melt adhesive establishes a very quick bond so that the fiber cement product bonded with foam can be moved and stacked in production.
In a preferred embodiment, the adhesive layer 106 is selected to accommodate the possible stresses generated by cyclic differential expansion between the foam and the fiber cement portions of the integrated fiber cement and foam insulation panel. In various embodiments, the adhesive can be applied onto the fiber cement layer by spraying, roll coating, etc. The adhesive layer 106 may be discontinuous, such as with partial coverage over the portion of the back surface 105 of the fiber cement layer 102 which mates to the profiled foam layer 104 to lead to a material and cost savings. A discontinuous adhesive layer 106 may also facilitate the evaporation of moisture from the interface between the elongate fiber cement layer 102 and the profiled foam layer 104 . In other embodiments, the adhesive layer 106 may be continuous, such as with full coverage over the portion of the back surface 105 of the fiber cement layer 102 which mates to the profiled foam layer 104 .
In another embodiment, the profiled foam layer 104 may be joined to the fiber cement layer 102 by laminating the profiled foam layer 104 to the interior surface or back face 105 of the fiber cement layer 102 . Lamination may be achieved by mechanical means, by use of adhesives or by forming the foam layer directly on the fiber cement layer either before or after curing of the fiber cement layer by autoclaving, depending on the materials used. In yet another embodiment, the profiled foam layer 104 can be formed by applying a layer of foam generating liquid to the interior surface or back face 105 of the fiber cement layer 102 and allowing the layer of foam generating liquid to expand such that the entire interior surface or back face 105 of the fiber cement layer 102 is substantially covered with foam. In this embodiment, the profiled foam layer 104 may be formed into a predetermined shape and profile after foam generation by use of routing, molding or machining equipment as is known to those skilled in the art. Alternatively, the profiled foam layer 104 may be formed by allowing the layer of foam generating material to expand into a mold or container of a predetermined shape or profile, followed by an operation that releases the foam layer from the mold or container.
With further reference to FIG. 1A , in various preferred embodiments, the profiled foam layer 104 can include drainage channels 112 extending through the exterior or interior of the foam to provide water drainage. The profiled foam layer 104 can also include profiled opposing longitudinal edges 110 , 111 . The profiled edges 110 , 111 are configured to interlock with corresponding profiled edges on adjacent profiled foam layers to facilitate alignment of the panels 100 during installation. In certain implementations, the interlocking features formed by the edges 110 , 111 of the profiled foam layer 104 are adapted to allow the panels 100 to nest with each other as they are assembled on a wall.
As described in greater detail below, in some embodiments, the interlocking features are specially configured to interlock in a manner that improves the wind load of the panels. As shown in FIG. 1A , one of the edges 111 of the profiled foam layer 104 is configured with a channel 115 defined by two parallel sidewalls 114 a , 114 b extending longitudinally across the edge 111 . The parallel sidewalls 114 a , 114 b in conjunction with the channel 115 formed in the profiled foam layer 104 interlock and secure the edge 110 of adjacent foam layers so as to improve wind resistance of the panel 100 . The interlocking features can also be adapted to provide an air seal, whether with or without use of sealants such as caulk or tape. In some embodiments, the interlocking feature can also be adapted to meet the requirements for continuous insulation and thermal break across the framing members. In some implementations, the interlocking features are also adapted to provide the installer a means to adjust joint spacing so as to efficiently space panels along the wall to reduce material use and installation labor.
FIG. 1B illustrates a manner in which a plurality of integrated fiber cement and foam insulation panels 100 a , 100 b can be arranged as assembled on a building frame to form an exterior cladding, such as for exterior siding applications. In various preferred embodiments, the panels 100 a , 100 b are prefabricated so that the installer can simply remove the packaging from each panel and attach the panels to the frame of a building. As shown in FIG. 1B , the panels 100 a , 100 b are positioned in a nesting configuration whereby the profiled edges 110 a , 111 a , 110 b , 111 b of the foam layers 104 a , 104 b interlock the panels so as to provide an air seal without sealer and to facilitate alignment and installation. The panels can be positioned such that the interlocking foam layers can provide continuous insulation and thermal break across the building framing members. As also shown in FIG. 1B , the drainage channels 112 allow water to drain from the interior of the panels 100 a , 100 b . The drainage channels 112 can be formed either on the interior or exterior surface of the foam layer or within the foam layer itself for effective water management within the wall cavities. In one implementation, the profiled foam layer 104 has a thickness of about ¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cement layer 102 has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175 cm). In one embodiment, the profiled foam layer 104 can have a density of between 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and an R value of between R3 and R7, preferably R3, such as R3, R5, and R7.
With further reference to FIG. 1B , in overlapping siding applications, the parallel side walls 114 a , 114 b on the lower edge 117 a of the profiled foam layer 104 a directly contact and enclose both side surfaces of the upper edge 119 b of the adjacent profiled foam layer 104 b , thus mechanically connecting the profiled foam layers 104 a , 104 b with each other, which in turn improve the wind load of the panels 100 a , 100 b . In one embodiment, both the upper and lower edges 117 a , 117 b , 119 a , 119 b of the profiled foam layers 104 a , 104 b have a sloped profile such that the parallel side walls 114 a , 114 b are not evenly disposed. Preferably, the sidewall 114 b in contact with the fiber cement layer 102 a , 102 b is positioned higher than the sidewall 114 a , 114 b not in direct contact with the fiber cement layer.
FIG. 2A illustrates an, integrated fiber cement foam and insulation panel 200 according to another embodiment of the present disclosure adapted for exterior siding applications in which the sidings are not in a nesting configuration. As shown in FIG. 2A , the panel 200 includes a fiber cement layer 202 and a profiled foam layer 204 attached thereto. The profiled foam layer 204 can be attached to the fiber cement layer 202 by an adhesive layer 206 or can be integrally formed on the fiber cement layer 202 . In this embodiment, the longitudinal edge 209 of the profiled foam layer 204 is substantially flush with the longitudinal edges 207 of the fiber cement layer 202 . As also shown in FIG. 2A , the foam layer 204 has interlocking features 210 , 211 adapted for aligning and coupling adjacent panels 200 during assembly, such as a tongue and groove joint. Additionally, drainage channels 212 can be formed in the foam layer 204 as shown in FIG. 2A . In certain preferred implementations, the thickness of the foam and fiber cement layers can be selected to provide target insulation R values and also allow the panels to be integrated into the building structure without requiring alterations of the wall or framing dimensions of existing building structures. In one implementation, the foam backing 204 has a thickness of about ¼ inch to 3 inches (0.635 cm to 7.62 cm) and the fiber cement layer has a thickness of about ⅛ inch to 1.25 inches (0.318 cm to 3.175 cm). In one embodiment, the foam backing 204 can have a density of between 1.25 to 2.0, such as 1.25, 1.5, 1.75, or 2.0, and can, have an R value of between R3 and R7, preferably R3, such as R3, R5, and R7. In one embodiment, siding nails from 6 d to 16 d can be used, such as 6 d, 10 d, and 16 d.
FIG. 2B illustrates one embodiment in which integrated fiber cement and foam insulation panels 200 can be arranged when they are assembled on a building frame to form an exterior cladding. As shown in FIG. 2B , the foam layers 204 a , 204 b can include interlocking features 210 ′, 211 ′ such as a tongue and groove, such that the fiber cement layers 202 a , 202 b form a substantially planar exterior surface. In some embodiments, the interlocking features in the foam layers may be formed using the same techniques as for forming drainage channels in a separate step. In addition, in the case of EPS foams, the polystyrene beads may be placed in a mold specifically designed to yield a foam panel having both drainage channels and interlocking features.
FIG. 2C shows an alternative embodiment in which the integrated fiber cement and foam insulation panels can be arranged when they are assembled on a building frame to form an exterior cladding. As shown in FIG. 2C , the fiber cement layers 202 a , 202 b can include interlocking features 210 ″, 211 ″ such that the fiber cement layers 202 a , 202 b form a substantially planar exterior surface. In the illustrated embodiment in FIG. 2C , the profiled foam layers 204 a , 204 b are configured without interlocking features. It should be appreciated that in various embodiments, either the profiled foam layers 204 a , 204 b and/or the fiber cement layers 202 a , 202 b can have interlocking features 210 , 211 .
In various embodiments, the fiber cement and foam insulation systems disclosed herein are designed with innovative water management mechanisms and improved ventilation functions to facilitate ventilation and drainage of water and other liquids from the wall cavity. As shown in FIG. 1A , the foam layer 104 may incorporate various drainage channels 112 . The drainage channels are designed to divert water away from the panels so as to prevent water from entering the home, prevent damage to the panels, and prevent the panels from attracting insects.
FIGS. 3A-3I are schematic illustrations of certain embodiments of the profiled foam layer 104 that is part of the integrated fiber cement foam and insulation panel 100 . In some embodiments, the profiled foam layer 104 has a first face 131 that is configured to be in direct contact with a fiber cement panel and an opposing face 133 that is set at an angle relative to the first face 131 so as to form an inclined surface relative to the fiber cement layer. The inclined surface facilitates mounting of the panels in a nesting configuration. In some other embodiments, the profiled foam layer 104 can be configured to allow stacking of the integrated fiber cement and foam panels during transit so as to reduce damage otherwise normally sustained by foam materials while in transit. As illustrated in FIGS. 3A-3D , the profiled foam layer 104 can include complementary angled edges to facilitate nesting. In one embodiment, an angle 134 measuring about 45 degrees relative to the vertical axis can be formed on the upper edge and a complementary angle 136 measuring about 135 degrees relative to the vertical axis can be formed on the lower edge. In some embodiments, the vertical axis can be the vertical axis of the integrated fiber cement and foam panel when the integrated fiber cement and foam panel is positioned or assembled on a building structure. In some other embodiments, the angles 134 , 136 can, be 0 to 90 degrees, 90 degrees to 180 degrees, 0 to 45 degrees, 45 degrees to 90 degrees, 90 degrees to 135 degrees.
In the embodiment shown in FIG. 3B , side 138 can have a range between 3.5 inches (8.9 cm) to 11 inches (27.9 cm), side 139 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 140 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.95 cm), side 141 can have a range between 0.25 inch to 1.25 inches (0.635 cm to 3.175 cm), side 142 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.95 cm), side 143 can have a range between 0.0625 inch to 0.375 inch (0.159 cm to 0.375 cm), and side 144 can have a range between 0.75 inch to 1.75 inch (1.91 cm to 4.45 cm). Angle 145 can have a range between 30 degrees to 60 degrees, angle 146 can have a range between 30 degrees to 60 degrees, and angle 147 can have a range between 1.5 degrees to 5.0 degrees.
In the embodiment shown in FIG. 3C , side 148 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 149 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 150 can have a range between 0.0625 inches to 0.375 inches (0.159 cm to 0.95 cm), side 151 can have a range between 0.625 inches to 1.75 inches (1.59 cm to 4.45 cm), and side 152 can have a range between 0.25 inches to 1.25 inches (0.635 cm to 3.175 cm). Angle 153 can have a range between 30° to 60°, angle 154 can have a range between 30° to 60°, and angle 155 can have a range between 1.5° to 5.0°.
In the embodiment shown in FIG. 3D , side 156 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 167 can have a range between 3.5 inches to 11 inches (8.9 cm to 27.9 cm), side 158 can have a range between 0.25 inches to 1.25 inches (0.635 cm to 3.175 cm), and side 159 can have a range between 0.625 inches and 1.75 inches (1.59 cm to 4.45 cm). Angle 160 can have a range between 30° to 60°, angle 161 can have a range between 30° to 60°, and angle 162 can have a range between 1.5° to 5.0°.
FIGS. 3E-3I depict additional profiles of foam layers that can be part of the integrated fiber cement foam and insulation panel.
FIGS. 3J-3N depict profiles of foam starter strips that can be placed at the bottom of a wall to start the proper kick out angle for installation of siding going up a wall.
In the embodiment shown in FIG. 3J , side 163 can have a range between 1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 164 can have a range between 0.0625 inches to 1.0 inches (0.16 cm to 2.54 cm), and side 165 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 166 can have a range between 30° to 60° and angle 167 can have a range between 1.5° to 5.0°.
In the embodiment shown in FIG. 3K , side 168 can have a range between 1.0 inches to 1.5 inches (2.54 cm to 3.81 cm), side 169 can have a range between 0.0625 inches to 1.0 inches, (0.159 cm to 2.54 cm) and side 170 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 171 can have a range between 30° to 60° and angle 172 can have a range between 1.5° to 5.0°.
In the embodiment shown in FIG. 3L , side 173 can have a range between 1.0 inches to 1.5 inches (0.159 cm to 2.54 cm), side 174 can have a range between 0.0625 inches to 1.0 inches (0.159 cm to 2.54 cm), and side 175 can have a range between 0.5 inches to 1.5 inches (1.27 cm to 3.81 cm). Angle 176 can have a range between 30° to 60° and angle 177 can have a range between 1.5° to 5.0°.
In various embodiments, the fiber cement and foam insulation panels disclosed herein are designed with innovative water management mechanisms to facilitate ventilation and drainage of water and other liquids from the wall cavity. With reference to FIGS. 4A-4D , in various embodiments, the drainage channels may take on a variety of patterns including grooves, designs or logos 113 . As depicted in the illustrated embodiments, the drainage channel patterns are formed on the back side of the foam layer 104 . However, it should be appreciated that in various embodiments, the drainage channels 112 and grooves, designs or logos 113 may be formed along any surface of the foam, or in other embodiments, through the thickness of the foam. The drainage channels, can be made by machining or hot wire cutting or a spindle molder with aluminum blades. The channels or features may also be formed using molding techniques such as injection molding. In alternative embodiments, the drainage channels 112 can take the form of an embossed or debossed feature in the form such as an image, symbol, design or logo. In another embodiment, the drainage channels can take the form of chevrons or tread designs. In some embodiments wherein thermoplastic foams, such as polystyrene foams, are used, the drainage channels 112 may be added by machining using a router or grinder or by using a hot wire, water jet cutting or laser cutting means. In the case of thermosetting foams, water channel routing, grinding, or injection molding techniques may be preferred. In yet other embodiments, such as foams made out of expanded polystyrene (EPS), the drainage channels may be incorporated into the mold used to form the foam. In other embodiments, such as foams made out of cut block EPS foam, the porosity of the foam can function as the drainage channels or to improve ventilation. In such embodiments, the foam porosity can be adjusted to allow drainage. As such, the foam according to some embodiments of the present disclosure may not require drainage channels.
FIG. 5 illustrates an integrated wall assembly 300 according to one embodiment of the present disclosure. The wall assembly 300 can include a sheathing 301 , such as oriented strand board (OSB), and a plurality of prefabricated fiber cement and foam insulation panels 300 a - e mounted to the sheathing 301 . The foam layer 304 on each panel interlocks with the foam layer on adjacent panels such that the fiber cement layers 302 are aligned in a nested configuration. In the embodiment shown in FIG. 5 , water draining channels 312 are formed on the front surface of the foam layer. In some embodiments, the drainage channels 312 can be formed on the back surface of the foam layer 304 , within the interior foam layer, or a combination of the front, back surface and/or interior of the foam layer. In other embodiments, the drainage channels may be formed on the back face of the fiber cement layer 302 . In yet other embodiments, the drainage channels may be formed in both the foam layer and the fiber cement layers. In some implementations, a layer of weather resistant barrier material 313 , such as those marketed under the HardieWrap® brand, can be positioned between the sheathing 301 and the foam layer 304 of the fiber cement and foam insulation panel 300 a - 300 e.
FIG. 6A illustrates an embodiment of a fiber cement and foam insulation trim corner 400 with an integrated fastening tab 416 . The trim corner 400 with the fastening tab 416 is for use around an outside corner of a building structure. FIG. 6B illustrates an embodiment of a foam insulation panel with an integrated fastening tab for use around an inside corner of a building structure. The fastening tabs 416 are configured for mounting the fiber cement and foam insulation trim corner to the building frame or other support structure without having to attach a fastener through the front face of the fiber cement layer 402 . As such, the fastening tabs 416 can be used so that the fasteners are concealed from view upon installation of the panels. The panels 400 may also be useful in installations where the wall does not include a sheathing to attach the panels. As shown in the illustrated embodiments in FIGS. 6A-6B , in some embodiments, the fastening tabs 416 can have one or more overhanging portions 417 extending outwardly from an edge of the foam layer to fasten to a support structure of a building (e.g., extending from the lateral edges of the foam layer). In one preferred embodiment, the overhanging portions 417 can be between 3-10 inches (7.62 cm-25.4 cm) in length, more preferably approximately 3 inches (7.62 cm) in length.
As shown in FIG. 6A and FIG. 6C , in some embodiments, the fastening tabs 416 can be arranged to be disposed between the fiber cement layer 402 and the foam layer 404 . In some embodiments, the fastening tab 416 is generally formed of a strip of metal shaped to follow the contours of the exterior or interior surface of the foam layer 404 .
With reference to FIGS. 6A-6B , and FIGS. 6D-6F in some embodiments, the fastening tabs 416 can have a one or more recesses or flat tangs or flanges 419 creating a notched or angled profile. The recesses 419 can allow the overhanging portions 417 to be flush with a surface of the foam and/or flush with mating components of the building to fasten to a support structure of the building. Preferably, the recesses 419 are between 0.25″ and 1″ in length. The fastening tabs can be installed in a manner such that at least a portion of each fastening tab is concealed from view when the wall panel 400 is installed on the building. The fastening tabs 416 can include angled or filleted corners 478 with radii between 1/32″ and 1/16″.
FIGS. 6D-6F illustrate embodiments of fastening tab 416 profiles.
FIG. 6D illustrates an embodiment of a fastening tab 416 profile for use in a fiber cement and foam insulation board installed around an inside corner. In one implementation, portions 421 a , 421 b of the fastening tabs 416 adjacent the foam layer can be between 3″ to 11.5″ (7.62 cm to 29.21 cm) ( 421 a ) and/or between 4″ to 11.5″ (10.16 cm to 29.21 cm) ( 421 b ), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm), as depicted in FIG. 6D . Such an embodiment can be used for inside corner installations.
FIG. 6E illustrates an embodiment of a fastening tab 416 profile for use in a fiber cement and foam insulation board installed around an outside corner. In one implementation, portions 421 a , 421 b of the fastening tabs 416 adjacent the foam layer can be between 1.5″ to 10.5″ (3.81 to 26.67 cm) ( 421 a ) and/or between 2″ to 11″ (5.08 cm to 27.94 cm) ( 421 b ), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm), as depicted in FIG. 6E . Such an embodiment can be used for inside corner installations.
FIG. 6F illustrates another embodiment of a fastening tab 416 profile for use in an integrated fiber cement and foam insulation panel. In one implementation, portions 421 of the fastening tabs 416 adjacent the foam layer can be between 3″ to 10″ (7.62 cm to 25.4 cm), the overhanging portions 417 can be between 3″ to 10″ (7.62 cm to 25.4 cm), preferably 3″ (7.62 cm), the recesses 419 can be between 0.25″ (0.635 cm) and 1″ (2.54 cm), and the edges 478 can have radii between 1/32″ (0.079 cm) and 1/16″ (0.159 cm) as depicted in FIG. 6F . Such an embodiment can be used for non-corner installations. It should be appreciated that in other embodiments, the length of the portion 421 of the fastening tabs 416 adjacent the foam layer can be sized to any dimensions necessary to match the foam layer length. In one embodiment, the overall thickness of the fastening tab 416 is between 16 to 20 gauge, preferably 18 gauge.
FIGS. 6G-6I illustrate embodiments of foam profiles for use with fastening tabs in fiber cement and foam insulation panels.
FIG. 6G illustrates an embodiment of a foam profile for use in an inside corner section of an integrated fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have an “L” shape configuration and can have a side length 479 between 3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 480 between 3.5″ to 13″ (8.89 cm to 33.02 cm), with thicknesses 481 , 482 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
FIG. 6H illustrates an embodiment of a foam profile for use in an outside corner section of a fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have an “L” shape configuration, and can have a side length 483 between 3.5″ to 14″ (8.89 cm to 35.56 cm) and a side length 484 between 1.5″ to 10.5″ (3.81 cm to 26.67 cm) with thicknesses 485 , 486 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
FIG. 6I illustrates an embodiment of a foam profile for use in a fiber cement and foam insulation panel with integrated fastening tabs. In such an embodiment, the foam layer 404 can have a length 488 between 1.5″ to 12″ (3.81 cm to 30.48 cm) with a thickness 487 between 0.25″ to 1.5″ (0.635 cm to 3.81 cm).
In some embodiments, the fastening tabs 416 can be attached to the panel 400 using one or more connecting elements. The connecting elements can include nails, staples, pins, rivets, screws, anchors, clasps, bolts, bucklers, clips, snaps, and other types of fasteners as in known to those of skill in the art. In yet further embodiments, the foam layer can include one or more recess features (not illustrated) in which the tabs are placed such that the tabs do not extend beyond the back wall of the foam layer. In some embodiments, the recess feature in the foam layer may be formed using the same techniques as for forming drainage channels and/or interlocking features in a separate step. In addition, the recess features may be formed out of a mold specifically designed to yield a foam layer having drainage channels, interlocking features, and recess features. In further embodiments, the fastening tabs 416 can attach the panel 400 to the support structure using at least one connecting element described above.
FIG. 7 illustrates yet another embodiment of the present disclosure showing a prefabricated panel 600 including a fiber cement layer 602 , a backing 622 and a foam layer 604 disposed therebetween connecting the backing 622 to the fiber cement layer 602 . In some embodiments, the hacking 622 preferably made out of OSB and can be laminated to the foam layer 604 . It will be appreciated that the foam layer 604 and/or the fiber cement layer 602 can incorporate various interlocking features to facilitate alignment and sealing of the adjacent layers and drainage channels to facilitate water management.
FIG. 8 illustrates yet another embodiment of the present disclosure showing an integrated fiber cement and foam insulation panel 700 incorporating a discontinuous layer 724 in the foam layer 704 a , 704 b . The discontinuous layer 724 can provide enhanced acoustic dampening properties, reducing unwanted outside noise and vibrations from entering the building and also reducing interior noises from leaving the building. Such an embodiment can act to give further privacy for occupants inside of the building. In some implementations, the discontinuous layer 724 can be made of a viscoelastic material. Preferably, the discontinuous layer 724 is attached to framing members of the wall to dampen vibrations from the exterior of the building from being transmitted to the interior of the building.
FIG. 9 illustrates a further embodiment of the present disclosure showing a prefabricated fiber cement and foam insulation panel 800 designed for high shear applications. The panel 800 includes a fiber cement layer 802 , a foam layer 804 , and a mesh 826 disposed therebetween for reinforcement. In some embodiments, the panel 800 can provide sufficient shear strength to eliminate or substantially reduce the need for structural sheathing, such as OSB. In other embodiments, the foam layers may include facing materials such as meshes or non woven, sheets to enhance the shear strength of the fiber cement and foam insulation panel 800 . In yet further embodiments, the panel 800 may also incorporate mesh or reinforcing fibers within the body of the foam layer. The panel may include vapor permeable facing materials adjacent the foam layer, including foils or films to reflect heat or heat loss due to air permeability.
FIGS. 10A-10C illustrate further embodiments of the present disclosure showing two fiber cement and foam insulation panels 900 a , 900 b joined together with a butt joint 926 . The panels include fiber cement layers 902 a , 902 b and profiled foam layers 904 a , 904 b . In this embodiment, the profiled foam layers 904 a , 904 b extend only a partial length of each respective fiber cement layer 902 a , 902 b , thus leaving a space on both ends of each fiber cement layer configured to receive an insert 928 . The insert 928 can be placed at the joint 926 to mitigate water penetration into the wall and allow condensation to drip over the face of the plank below the lap siding. The insert 928 can include a foam layer 932 laminated with a piece of house wrap or flashing 930 . The flashing 930 may be used as a water resistive barrier. The flashing 930 can be constructed to be longer than the foam layer 932 such that when joined together to form the insert 928 , the flashing includes an overhang 931 which extends beyond a length of the foam layer 93 (best depicted in FIG. 10B ). In one preferred embodiment, the foam layer 932 of the insert 928 can have a nominal width of 6 inches (15.24 cm) and the flashing 930 can have an overhang 931 of approximately 1.16 inches (2.95 cm). In one embodiment, the insert 928 can include a foam layer 932 having a profile that matches the profile of the mating foam layers 904 a , 904 b of the adjacent panels 900 a , 900 b.
FIGS. 11A and 11B are schematic illustrations of certain connection mechanism that can be used to join adjacent integrated fiber cement and foam panels 1100 a , 1100 b at a butt joint. In one embodiment, a recess 1101 a , 1101 b is formed along the lateral edges of each panel 1100 a , 1100 b . Each recess is configured to receive a portion of an insert 1102 a , 1102 b designed to join the two panels. The insert 1102 a , 1102 b can assume a variety of different shapes and configurations. In one embodiment, the insert 1102 b is an elongate planar member that can be made out of foam, fiber cement, or other material. The insert 1102 b can be inserted between the two panels and slidingly engage with the recesses formed on the edge of each panel. In some embodiments, the insert 1102 a is keyed to mate with corresponding patterns in the recess 1101 a , 1101 b so as to interlock and further secure the two panels.
FIG. 12 depicts a flow diagram of installation 1000 of fiber cement and foam insulation panels on a wall according to one embodiment. The method includes cutting and trimming 1002 starter strips. As described above, starter strips can be used to ensure a consistent plank angle for the integrated panels. The method next includes installing 1004 the starter strips at the base of the wall. Starter strips may be fastened to the wall using one or more fasteners described above (e.g. siding nails from 6 d to 16 d). The starter strips may be fastened to a sheathing (when present) or directly to the studs of the building. The method further includes cutting and trimming 1006 the integrated fiber cement and foam insulation panels. The method next includes installing 1008 the fiber cement and foam insulation panels to the wall. In some embodiments, as described above, the panels can include interlocking features for nesting or crotchedly connecting the panels. In some embodiments, as described with reference to FIGS. 6A-6I , panels incorporating fastening tabs can be used. As described above, fastening tabs may be useful in installations where the wall does not include a sheathing to attach the panels to conceal the fasteners. The method optionally includes installing 1010 inserts at the butt joints between adjacent panels, as described with reference to FIGS. 10A-10C and 11A-11B . As described above, the inserts can include a flashing to act as a water resistive barrier.
FIG. 13 illustrates yet another embodiment of an integrated fiber cement and foam insulation panel 1300 . The panel 1300 generally includes two fiber cement layers 1302 a , 1302 b and a profiled foam layer 1304 disposed therebetween. The fiber cement layers 1302 a , 1302 b can be attached to opposing faces of the foam layer 1304 via a suitable adhesive. As shown in FIG. 13 , the thickness of the foam layer 1304 can be substantially greater than the thickness of the fiber cement layers 1302 . In some embodiments, the foam layer 1304 includes profiled edges configured to mate and interlock with corresponding edges on adjacent panels, thereby forming a continuous surface. The panel 1300 is preferably pre-fabricated so that it can be used readily at the construction site.
The advantages of the prefabricated integrated fiber cement and foam composite insulation panel include a higher R-value fiber cement building material that is easily installed, provides a building envelope that resists penetration from the elements yet can breath and drain water away from the interior, and a faster installation time when a builder decides to use foam insulation on the structure.
To avoid over-compression and distortion when attaching the integrated fiber cement and foam panels to a wall, the foam preferably has a minimum compressive strength of about 15 psi as determined by ASTM D 6817. In some embodiments, to ensure that the integrated fiber cement and foam system has a minimum wind load resistance of 3.0 kPa ultimate load when tested using an ASTM E 330 vacuum testing apparatus, the minimum compressive strength of the foam is preferably about 15 psi as determined by ASTM 6817. In one embodiment, an integrated fiber cement and foam insulation cladding panel, formed in accordance with the designs disclosed herein, has a wind load of greater than 83 psf, preferably greater than or equal to 94 psf.
The foregoing description of the preferred embodiments of the present disclosure has shown, described and pointed out the fundamental novel features of the inventions. The various devices, methods, procedures, and techniques described above provide a number of ways to carry out the described embodiments and arrangements. Of course, it is to be understood that not necessarily all features, objectives or advantages described are required and/or achieved in accordance with any particular embodiment described herein. Also, although the invention has been disclosed in the context of certain embodiments, arrangements and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments, combinations, sub-combinations and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of the embodiments herein.
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An integrated fiber cement and foam cladding system is provided that incorporates foam or similar light weight material to improve the insulation capacity of the cladding system. The system includes at least a fiber cement layer and a foam layer disposed on the backside of the fiber cement layer. The system improves the R-value of the building, a measure of the building's resistance to transferring heat or thermal energy.
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RELATED APPLICATION
This application is a divisional application of co-pending application Ser. No. 10/754,255 filed Jan. 9, 2004, which claims benefit of U.S. provisional application 60/458,488 filed Mar. 28, 2003.
FIELD OF THE INVENTION
The invention is related to underwater ocean current Hydro-Electric farms and the electrical generators used for such farms.
BACKGROUND OF THE INVENTION
The problem with underwater ocean current flow power conversion to electric energy up to now has been that the electric generators had to be shielded from the ocean water, either by placing them above the surface of the water or enclosing them in watertight containers.
SUMMARY OF THE INVENTION
What is needed is a new and unique invention that can use a direct ocean water immersion type of electrical generator. These generators can incorporate either an internal framework with the stator wire coils attached to and wound around this framework, which can then support this new assembly, or the more conventional exterior supported coil wire arrangement, sometimes known as the clamshell type arrangement.
The exterior and interior surfaces of this new generator is coated with a new combination of composite layers to form a non-conductive, heat dissipating, anti-fouling, caustic water environment specific, protective coating thus allowing the entire apparatus sustained immersion in the ocean water.
These generators are designed to allow the ocean current to pass through their shapes to further aid in heat dissipation. Air based generators are limited by heat in the amount of electrical current they produce. In this invention, by allowing the water to flow around the windings and increase the generated heat dispersion, it can produce larger amounts of electric current from the same size generator with industry standard windings.
These electrical generators could also incorporate the use of a brush-less design, whereas the rotator components are never actually in contact with the stator assembly. The extended life of each unit and each individual component is one of the overall design goals of this invention.
These electric generators are self-contained and modular in aspect. Replacement of most components involves the removal of the entire electrical generator and turbine blade/propeller assemblies and plugging in a replacement combined unit. Service of the combined units can be on either specially equipped ships and/or serviced on the mainland, depending upon the extent of the repairs required. Spare assemblies can be ready in advance to facilitate removal and replacement of malfunctioning units with a minimum of downtime. The Hydro-Electric Farm as a whole only loses the generating capacity of the individual assembly that is being replaced.
This plug-in unit capacity can only be accomplished with the generator-supporting replacement-friendly cradles. These cradles are pre-assembled, transported to the site location and then lowered into position ready to receive the generator assemblies. Cradles are attached to the ocean bottom with pile anchors. They can be driven, mechanically or power charged, augured or vibrated into position.
Placement of the electric generators minimizes environmental and boat traffic concerns. Other placement criteria include: a) degree of slope of the bottom which could be anywhere between vertical and horizontal, b) actual composition of the bottom, c) placement proximity to final use of the generated electricity, d) location of optimum constant ocean current.
The electric generators are powered by a composite turbine blade/propeller that converts the ocean current's kinetic energy into rotational force. The rotational blades are large and slow moving, but with substantial torque, this kinetic energy then is applied to the rotational shaft on which they turn. This shaft is coupled to, or is a part of, a gear up rotational enhancer to maximize the electric generator's output. These turbine blade/propeller assemblies are constructed of either non-corroding metals, space age composite materials and/or coated with a protective type coating similar to that used on the electric generators.
The metals incorporated in the design of these electric generating units and in their cradle design are preferably non-corroding alloy metals.
The power transmission lines from each Hydro-Electric Farm converges and unifies and then is routed to the mainland under land and water surface thru directional drilled conduits. The advantages of this arrangement are numerous. The described turbine blade/propeller driven electric generator, cradle, anchoring piles and transmission lines are located in plural. Directional drilling from the mainland sites places the transmission line conduit under the mainland and ocean surface.
The power control equipment, voltage regulators, converters and accumulators are located inland and adjacent to the conventional power grid system.
This invention and process is composed of predominately new art coupled with some prior art combined in a unique and exciting new manner to produce renewable electric energy from ocean currents. This new combination includes, but is not limited to: totally immersed electric generators powered by ocean currents that have new internal structures and support components, coated with non-conductive, heat dissipating, anti-fouling, water environment specific, protective coatings, employment of new turbine blade/propellers, (multiple styles are shown), setting of these submerged generators, (two types are shown), on pre-constructed cradles, (two types are shown), anchoring of these cradles in the current's flow, constructing the generator and turbine blade/propeller as a combined replaceable unit, employing directional drilling to route the transmission cables, using water specific electric cable types, employing a junction platform (transfer station) for mid ocean deployment, and grouping these electric generators in multiple placement formations that are known as Hydro-Electric Farms.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a Cross-Sectional View of an Adjacent Site Hydro-Electric Farm;
FIG. 2 is another embodiment of the invention in cases where the ocean currents are not directly adjacent to the mainland, in which an intermediate platform (transfer station) is incorporated where the platform is bottom supported. Alternatively, the transfer station may be of a submersible, or semi-submersible type structure, or a combination of the three types;
FIG. 2 a is a side view of the conventional bottom supported intermediate platform;
FIG. 2 b is a side view of the a submersible type intermediate platform;
FIG. 2 c is a side view of the a semi-submersible type intermediate platform;
FIG. 3 is a plan view of a Hydro-Electric Farm in which the ocean current is in close proximity to the mainland shoreline;
FIG. 4 is a side view of the internally supported electric generator assembly, including the turbine blade/propeller, in whichever style selected, being omitted, (see the omit line at the end of the turbine blade/propeller shaft), to focus on the electric generator and it's corresponding parts;
FIG. 5 shows a cross-sectional view of the internally supported electric generator, as shown in FIG. 4 ;
FIG. 5 a is an exploded or expanded view of the top portion of the internally supported electric generator, as shown in FIG. 5 as the area to be highlighted in the expansion circle;
FIG. 5 b is an exploded or expanded view of the Brush-Less Rotator Assembly as if it were pulled forward from the front of the standard rotator;
FIG. 6 is the side view of an externally supported (stator) field wound electric generator, the turbine blade/propeller being omitted (see the omit line at the end of the turbine blade/propeller shaft), to focus on the electric generator and its corresponding parts;
FIG. 7 is a cross-sectional view along cut line (B—B) of FIG. 6 of the externally supported electric generator;
FIG. 8 is side view of the internally supported electric generator as it sits on the pre-manufactured cradle, again with the turbine blade/propeller being omitted to focus on the electric generator and the corresponding cradle;
FIG. 8 a is side view of a concrete cradle mounted with an internally supported electric generator;
FIG. 8 b is a cross-sectional along cut line (C 1 —C 1 ) showing the internal components of the Magnetic Force Support Points;
FIG. 9 is a cross-sectional along cut Line (C—C) of FIG. 8 of the internally supported electric generator on the pre-manufactured concrete cradle;
FIG. 10 is a side view of an externally supported electrical generator on the pre-manufactured concrete cradle;
FIG. 11 is a cross section along cut Line (D—D) of FIG. 10 ;
FIG. 12 shows the internally supported generator attached to a different type cradle system, again with the turbine blade/propeller being omitted to focus on the electric generator and the corresponding cradle;
FIG. 13 is a cross-sectional view along cut line (E—E) of FIG. 12 of the internal supported electric generator mated with the open web cradle;
FIG. 13 a is a front view of the extended open web cradle with the internal supported electric generators arranged side by side. The cut line (G—G) has abbreviated the length of the extended cradle in the drawing;
FIG. 13 b is a plan view of the extended open web cradle system showing placement of the internal supported electric generators arranged side by side. The cut line (H—H) has abbreviated the length of the extended cradle in the drawing;
FIG. 14 is a side view of an externally supported electric generator placed on an open web cradle, again with the turbine blade/propeller being omitted to focus on the electric generator and the corresponding cradle;
FIG. 15 shows a cross section of an externally supported electric generator placed on an open web cradle along cut line (F—F) of FIG. 14 ;
FIG. 16 shows the placement of a Turbine Blade Propeller style on the blade spindle, connected to the end of the turbine blade/propeller shaft, which powers an internally supported electric generator;
FIG. 17 is the front view of the Turbine Blade Propeller style noted in FIG. 16 and which has in a rotational configuration eight individual blades pitched and overlapped in order to maximize conversion to rotational movement;
FIG. 18 shows the placement of a Propeller Weave Rotational Unit style, on an internally supported electrical generator;
FIG. 19 is the front view of the Propeller Weave Rotational Unit style noted in FIG. 18 ;
FIG. 20 is a side view of The Box Blade Weave Propeller style;
FIG. 21 is the front view of Box Blade Weave Propeller style of FIG. 20 ;
FIG. 22 is the side view of the Box Blade Solid Vane Propeller style;
FIG. 23 is the front view of the Box Blade Solid Vane Propeller style of FIG. 22 ;
FIG. 24 is the side view of The Skeletal Spiral Turbine style;
FIG. 25 is the front view of the Skeletal Spiral Turbine style of FIG. 24 ;
FIG. 26 is the side view of the Multiple Three Blade Configuration style; and
FIG. 27 is the front view of the Multiple Three Blade Configuration style of FIG. 26 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 : Cross Section View of an Adjacent Site Hydro-Electric Farm. Shown in this view is the direct immersion type of electrical generator 12 . The exterior and interior surfaces of this generator is coated with a protective covering 19 . Also shown are the composite turbine blade/propellers 13 , the ocean current 17 , pre-assembled cradle 16 and the pile type devices 15 . This anchoring system can be used either horizontally into the side of the underwater channel drop-offs 8 or vertically into the bottom of the current channels 26 . The layout of the multiple generators is based on current flow 17 and the required design minimum depth 18 for the generator assemblies 12 / 13 , from the ocean surface 7 .
The power transmission lines to the mainland are via under water transmission cables 11 that are pulled thru the directional drilled conduits 6 . Close to the mainland, these transmission lines are routed through the entrances 9 of the conduits 6 , to sites set well back from the coastline 5 and the shoreline buildings 4 . These conduits emerge at 10 which is where the power regulators and conversion equipment (also referred herein as control segment) 3 is housed, and the standard mainland transformers 2 and transmission lines 1 are located.
The described electric generators 12 are located in plurality in an array arrangement. Control wirings 14 interconnect these multiple electric generators 12 .
FIG. 2 : In areas of the world where the ocean currents are not directly adjacent to the mainland, there can be placed an intermediate junction platform (transfer station) 22 , somewhat like the modern oil drilling platform, in which the platform may be bottom supported, as shown in FIG. 2 , or of a submersible type, or semi-submersible type structure, or a combination of the above types, depending upon the depth of the ocean current 18 from the surface 7 , the conditions of the bottom, and other factors. These platforms collect and transform the harvested electricity into the proper configuration for long distance transmission to the mainland. The incoming, direct bottom laid, power accumulated transmission line 20 is routed up the platform 21 and then converted in the control segment 3 of the platform 22 to long distance transmission configuration. The power is then routed back down the platform 23 and to the mainland via the ocean bottom laid transmission cables 25 . When this cable 25 reaches proximity to the coastline it can then be routed into the same type of conduit opening 9 located in the naturally occurring ocean bottom 8 , thru the incoming conduit 6 , along with or be transformed into, part of the standard transmission cable 11 , and then up to the above ground emergence point 10 . The rest of the generation, collection, combining and transmission aspects of the collective Hydro-Electric Farm as depicted in FIG. 1 , will apply to finally feeding the electricity generated into the mainland electric power grids 1 . We have not retraced the common and identical components in both FIG. 1 and FIG. 2 , as they are similar and the concepts are alike. The conduit 6 may be shorter or longer based on the particular generating site's ocean bottom characteristics and location of the mainland emerging point 10 , its distance from the underwater conduit pull point 9 , which is influenced by the ocean bottom depth 8 . The control wiring and generator monitoring functions are handled from the adjacent platform 22 , rather than from the mainland site as in FIG. 1 . The overall electric generating principles apply in FIG. 1 and FIG. 2 .
FIG. 2 a : This is a side view of the standard intermediate junction platform that is bottom supported. This has been discussed in length above. The permanent built in place bottom supported platforms are well known in the oil drilling art.
FIG. 2 b : This is a side view of a typical towed into place submersible intermediate junction platform that becomes tethered to the bottom in a semi-permanent placement. The drawing shows the exterior skin removed to reveal the interior spaces. The surface buoy for communications, anchorage of junction platform servicing ships and location of the submersible junction platform is shown as 83 . The docking port for underwater submersible craft to supply men and materials to the submersed junction platform is shown as 84 . The main temporary living, material storage and equipment areas are shown as 85 . The water filled stabilizing pontoons or ballast chambers are denoted as 88 . The structural cross bracing members bracing and tying the main junction platform chamber with the ballast chambers are shown as 90 . The submersible platform's bottom tethers are shown as 89 . The submersible platform's bottom support struts are shown as 86 . The tether bottom anchorage points are shown as 91 . The bottom is shown as 26 . The power from the Hydro-Electric Farm being serviced is routed into the submersible platform and is shown as 21 . The electrical transformation equipment in the control segment is shown as 3 . The configured outgoing power is then routed out of the structure 23 to the outgoing transmission lines to the mainland. These submersible platforms are known in the deep-sea exploration and the under sea habitat art. This is a new and unique use for this technology.
FIG. 2 c : This is a side view of a semi-submersible intermediate junction platform. These intermediate junction platforms are typically towed to remote ocean locations. Quite often these intermediate junction platforms 2 c are placed over very deep water. The design allows for the hollow pylons and pontoons to be filled with water thus sinking them under the surface of the ocean. This feature allows for the junction platform to remain steady even in sever weather. The water filled pylons are shown as 87 and the connecting water filled pontoons are shown as 88 . The tether lines to the bottom are shown as 89 and the bottom anchoring points are shown as 91 . The structural cross members bracing the platform 22 above and between the pylons 87 and the pontoons 88 is shown in this drawing by the designation of 90 . The stabilizing conduit for the incoming electrical cables 21 and the outgoing cables 23 is shown as 92 in this drawing. These deep-water platforms are also known in the oil drilling art.
FIG. 3 : This is a plan view of a Hydro-Electric Farm 24 in which the ocean current 17 is in close proximity to the mainland shoreline 5 . It shows the placement of the electric generators 12 , the control wiring 14 , the turbine blade/propellers 13 , the concrete cradles 16 , the pile anchoring system 15 , the ocean current 17 , the sloping ocean bottom is depicted as a line 8 , and the ocean current's channel is depicted as the rapidly changing topographical lines 26 . Notice how in this configuration the rows of electrical generators 12 are staggered so each individual generator and the turbine blade/propeller 13 are placed in a clean flow of ocean current water. This staggered configuration also accommodates the flowing water's natural phenomenon of a water current closing back in on itself a short distance after encountering an obstruction and then resuming its natural flow path again with minimal loss of the current's forward momentum. This resumption point is where another generator 12 and turbine blade/propeller 13 are placed to again harvest the energy of the flowing ocean current. This resumption flow point, for the next row of generators 12 , placement spot is behind the first two staggered rows and maybe in line with the first row's generator, but placed some distance to the rear. The placement of the electric generators on this closing and resumption of the current's path and energy dictates individual generator placement throughout the entire field of generators on a typical Hydro Electric Farm 24 . This plan also shows the relationship of the shore 5 with the sloping bottom of the ocean 8 , the rapid topographical changes 26 , after crossing the shoulder of the current's trench 8 , and the placement of a Hydro-Electric Farm 24 on the slope of this trench, either on the sloping walls or on the floor, depending on optimal depth 18 from the surface 7 and most constant flow of the ocean current 17 .
FIG. 4 is a side view of the internally supported electric generator assembly 12 , including the turbine blade/propeller 13 , in whichever style selected, has been omitted, (see the omit line at the end of the turbine blade/propeller shaft 29 ), to focus on the electric generator 12 and its corresponding parts. The internal field windings support rings 33 , rotator electromagnet assembly 27 , and the turbine blade/propeller shaft 29 , have been pulled forward along the Z–Z 1 , line in order to clearly show the internal components listed above. The rest of the electric generator 12 has the standard parts as already described, starting with the protective coating (schematically depicted as solid black surfaces) 19 , the rotator electromagnet assembly 27 , the turbine blade/propeller shaft 29 , the rotator electromagnet supports on the shaft 30 , the electromagnets 35 , the stator field windings 32 , the stator field windings support rings 33 and the generator cradle docking support struts 34 .
FIG. 5 shows a cross section along Cut line (A —A) of the internally supported electric generator 12 , as shown in FIG. 4 . The rotator electromagnet portion 27 of this electric generator is exposed to the water currents via the open passages 28 and the same non-conductive, heat dissipating, anti-fouling, water specific, protective coating 19 also protects its exposed surfaces. The protective coating 19 is comprised of multiple layers in order to achieve multiple design goals. The primary layer is designed to provide non-conductivity of large electrical voltages. The secondary layers bind the non-conductivity layers to anti-fouling, water specific, protective layers. Such protective coatings are known in the art and are typical of those marine coatings used in the shipbuilding industries, military ships and barges, etc. These anti-fouling protective layers provide the protection required specific to each site's location. The composite layers are thermally conductive in order to cool the generator as described above. The protective coating is applied to the generators and other required components by a combination of application methods; Dipping, spraying, brushing, powder coating, or in a combination of these methods. The coating composition is designed for the specific salt concentration, the organic and inorganic make up of local elements present and site specific temperature of the water, as well as many other environmental factors for each Hydro-Electric Farm location. The rotator electromagnet assembly 27 is made up of the rotator electromagnet's support and anchoring structures 30 , the rotator electromagnets 35 , and the rotating turbine blade/propeller shaft 29 . The other components shown in this cross section are the field windings (stator) 32 , the field windings support rings 33 , the entire electric generator assembly 12 , and the electric generator cradle docking support struts 34 .
FIG. 5 a is the expanded view of the top portion of the internally supported electric generator 12 , cross cut (A—A), as shown in FIG. 5 as the area to be highlighted in the expansion circle. This expanded view shows the protective coating 19 removed from the field windings (stator) 32 , the field windings support rings 33 , the support ring connectors 93 , the bolts 94 that hold the support ring and connectors together, the stator winding cores 95 and the rotator's electromagnets 35 . The overall electric generator assembly 12 is partially shown in this circular expanded view, both the coated portion and the uncoated portion.
FIG. 5 b is an expanded view of the Brush-Less Rotator Assembly 74 as if it were pulled forward from the front of the standard rotator 27 . The main components of this brush-less assembly are the transmitting ring 67 , with its transmit nodes 68 , the protective spacer ring 69 , with its correctly placed spaces (apertures) 70 , and the reception ring 71 , with the reception nodes 72 , connected to the reception tabs 73 that are embedded into the windings of the electromagnets 35 that have been previously discussed in the internally supported electric generator 12 . This brush-less assembly and its components are also coated with the protective coating 19 , where required. Obviously, the transmit nodes 68 and the reception nodes 72 are not coated and are constructed from naturally occurring non-corrosive materials that can continue to transmit the electrical charge to power the rotator's 27 electromagnets 35 . The reception tabs 73 are locked into the corresponding internal wired grid of the electromagnets 35 , as in a conventional rotator 27 , this has not been shown, as it is standard in the industry. The electrical energy that the transmitter nodes 68 fire to the reception nodes 72 is supplied via internally wired circuits in this particular portion of the turbine blade/propeller shaft 29 . These electrical charges required for the electromagnets 35 to maintain their polarity are fired the short distance between the transmitting nodes 68 and the reception nodes 72 through the protective spacer ring 69 letting the ocean water provide the electrical connection between. These nodes and their corresponding attachment rings and the spacer ring 69 provide the shortest point between the transmitting nodes 68 and the reception nodes 72 in this defined space, and yet are part of the water environment. Again, the ultimate goal is to design as many non-contact mechanical elements into the Hydro-Electric Farm as possible.
FIG. 6 is the side view of an externally supported (stator) field wound electric generator 38 , the turbine blade/propeller has been omitted (see the omit line at the end of the turbine blade/propeller shaft 29 ), to focus on the electric generator 38 and its corresponding parts. The external shell (clamshell type arrangement) 36 supports the field winding much as in a conventional air-cooled electric generator. In this immersion electric generator configuration the shell and internal parts are protected by the non-conductive, heat dissipating, anti-fouling, water specific, protective coating, 19 . The ocean water is encouraged to flow around the field windings 32 , the electromagnetic rotator assembly 27 , the shaft 29 and supports 30 , and in and out of the external support shell 36 through openings in the external shell 37 , and through the front and rear of the shell. The field windings and electromagnets naturally have spaces between their individual components that also allow the water access around them inside the shell 36 . The field windings and cores are attached to the exterior shell with non-corrosive rods and bolts 47 . The internal parts have not been pulled out of the shell in this drawing, as they are similar to the parts already shown in FIG. 4 except for not having the internal field winding support rings 33 . The externally supported electric generator 38 are interchangeable with the internally supported generator 12 . In many of the drawings we have depicted the electric producing generators as type 12 for simplicity. The same principles also apply for the externally supported electric generators 38 .
FIG. 7 is a cross section view along cut line (B—B) of FIG. 6 of the externally supported electric generator 38 . The internal parts are visible and are similar to the internally supported electric generator 12 , except the absence of the field winding support rings 33 , this support is again completed by the external shell arrangement 36 . The other standard electrical generator parts of the internally supported electric generator 12 , as shown in FIG. 5 are present in this design. The turbine blade/propeller shaft 29 is in the center, with the electro-magnets 35 attached to it by means of the shaft magnet supports 30 . Water passages 28 are between the field windings 32 and the rotator assembly 27 . The external shell 36 supports the field windings 32 . Water passages 28 are in between the field windings 32 , the exterior shell 36 and the outside ocean current 17 . Again, this design increases production of electrical power by keeping the winding's insulation cooler than an air environment electric generator. The same coating 19 protects the externally supported electric generator 38 exposed surfaces to the ocean water, as mentioned previously. The externally supported electric generator 38 also employs the cradle docking support struts 34 . This feature is also crucial to the modular replacement of the generating units 38 and 13 , as a replaceable unit, similar as replacing 12 and 13 , as previously described.
FIG. 8 is a side view of the internally supported electric generator 12 as it sits on the pre-manufactured cradle 16 , again the turbine blade/propeller has been omitted to focus on the electric generator 12 and the corresponding cradle 16 . This view shows the concrete cradle 16 , the cradle docking support struts 34 , the cradle docking pins 45 , the cradle anchoring piles 15 , the turbine blade/propeller shaft 29 , the cradle rotational shaft mounting module 39 , the mounting module's release mechanism 40 , the shaft rotational gear up unit 41 , the electric generator's rotational shaft stabilizer 42 , the electric generator's internal frame connection 43 to the rotational shaft stabilizer 42 , the electric generator 12 , the protective coating 19 , and the placement on the ocean bottom as depicted by 26 . The cradle rotational shaft mounting module 39 , the shaft rotational gear up unit 41 and the electric generator's rotational shaft stabilizer 42 in the conventional arrangement are in contact with the turbine blade/propeller shaft 29 . Conventionally these rotational support-bearing points would necessitate the use of hardened bearings and races. These components may be the only items that necessitate special protection from the ocean water.
FIG. 8 a is a side view of a concrete cradle 16 mounted with an internally supported electric generator 12 . The outer covers of the rotational shaft mounting module 39 and the electric generator rotational shaft stabilizer 42 have been striped away to show the magnetic force support points 75 . These magnetic force support points 75 are mounted in multiple units along the turbine blade/propeller shaft 29 as required to support the multiple types of turbine blades 13 , shaft 29 , gear up unit 41 , brush-less rotator assembly 74 and the rotator assembly 27 .
FIG. 8 b is a cross section along cut line (C 1 —C 1 ) showing the internal components of the Magnetic Force Support Points 75 . The corresponding components are as follows: First there is the outer ring electromagnets 78 , the outer electromagnetic induced polarity 79 , the outer ring magnet control and power wiring 81 , the protective coatings 19 , the water passage between the inner and outer magnetic rings 28 , the inner electromagnetic ring 76 , the inner ring control wiring 80 , the inner ring induced polarity 79 , the turbine blade/propeller shaft coupler 82 . This is based on the simple principle that like kind polarity magnetic fields repel other like kind polarity magnetic fields. The shaft stabilizer units 42 and the rotational shaft-mounting module 39 capture the outer ring's electromagnets 78 and hold them in place. The inner electromagnetic ring 76 is attached to, via the coupler 82 , and become a part of the rotational mass, including the shaft 29 . The electric force is calibrated for rotational pull, mechanical pull and the overall weight to be supported at depth in order to permanently suspend the rotational shaft 29 within the center of the outer electromagnetic ring 78 . Wiring to these electromagnets is accomplished by the use of the brush-less FIG. 5 b , concepts already discussed above.
Some other design alternates of these metal to metal contact points are as follows: One solution to protect these support and turning shaft points from the ocean water environment would be to enclose conventional rotational bearing races in a sealed container filled with an inert gas under pressure, thus resisting water intrusion into the races. And of course, a more common solution is to support the turbine blade/propeller shaft 29 , in a more conventional nature in which the rotational bearings and races that are required are constructed from very dense non-corroding composite materials or metals. These materials maybe of alloyed metals, ceramics and/or other substances selected for their design qualities in this particular use.
FIG. 9 is a cross section along cut Line (C—C) of FIG. 8 of the internally supported electric generator 12 on the pre-manufactured concrete cradle 16 . It shows the cradle docking support struts 34 mated with the corresponding recess 31 secured by the docking pins 45 in the pre-manufactured concrete cradle 16 . The other components have already been discussed in length above.
FIG. 10 is a side view of an externally supported electrical generator 38 on the pre-manufactured concrete cradle 16 . This drawing also depicts the standard parts that are listed above and shows the interchangeability of the internal electric generator 12 and the externally supported generator 38 .
FIG. 11 is a cross section along cut Line (D—D) of FIG. 10 . The commonality of the parts has been previously discussed. This again shows the interchangeability of the electric generators 12 and 38 .
FIG. 12 shows the internally supported generator 12 attached to a different type cradle system 44 , again the turbine blade/propeller has been omitted to focus on the electric generator 12 and the corresponding cradle 44 . These open web cradles 44 are constructed of structural members of either non-corrosive composites or metals or be coated with the protective coating 19 . The docking pins 45 are the connection between the cradle's docking support struts 34 and the open web cradle 44 . In this open web cradle 44 design, the anchoring piles 15 are mated to the frame of the cradle with an adjustable pile restraint cap 46 . They are closed after the piles have been placed into the ocean bottom. This allows the open web cradle 44 to resist the ocean current 17 . The other parts of the open web cradle 44 and electrical generator 12 are the same as shown and discussed above in FIG. 8 and before. The open web structural members allow more ocean current 17 to pass thru the cradle than the concrete cradle design 16 , as has already been discussed.
FIG. 13 is a crosscut view along cut line (E—E) of FIG. 12 of the internal supported electric generator 12 mated with the open web cradle 44 . Note the cradle docking support struts 34 and the docking pins 45 . The anchoring piles 15 are also captured with the pile restraint caps 46 . The other components shown are also the same as already discussed above.
FIG. 13 a is a front view of the internal supported electric generator 12 arrayed in unison side by side on an elongated open web cradle 44 a . The common components have already been discussed above. This arrangement allows the elongated open web cradle to act as a suspension bridge and support these multiple electric generators 12 across a longer reach of sloping topographical bottom 26 . The length of the extended open web cradle 44 a has been truncated by the cross cut line (G—G). These open web cradles are sized for length and number of supported electrical generators 12 for each individual farm's unique design criteria.
FIG. 13 b is a plan view of the open web cradle 44 a showing the elongation and placement of multiple electric generators 12 . The length of the extended open web cradle 44 a has been truncated by the cross cut line (H—H). Again, the common elements have been discussed above. The extended open web cradles, in some instances are connected with other extended open web cradles, side-to-side and front-to-back, based on each individual farm's criteria. The design of number of electric generators 12 placed at each farm is unique to each individual Hydro-Electrical Farm site.
FIG. 14 is a side view of an externally supported electric generator 38 placed on an open web cradle 44 , again the turbine blade/propeller has been omitted to focus on the electric generator 38 and the corresponding cradle 44 . The components are the same as previously discussed including: the rotational shaft 29 , the shaft mounting module 39 , the mounting module release mechanism 40 , the shaft rotational gear up unit 41 , the electrical generator mounted shaft stabilizer 42 , the cradle docking support struts 34 , the docking pins 45 , the adjustable pile restraint cap 46 , and the externally supported shaft stabilizer mounts 47 . It should also be noted here that the open web cradle 44 design would also lend itself to multiple electric generator 38 placements on a single open web elongated cradle 44 a . The elongated open web cradle 44 a then acts as a suspension bridge to support these multiple electric generators 38 across a longer reach of sloping topographical bottom 26 . This again, depicts the interchangeability of the electric generators 12 and 38 .
FIG. 15 shows a cross section of an externally supported electric generator 38 placed on an open web cradle 44 along cut line (F—F) of FIG. 14 . The parts as labeled have already been discussed in detail above. To recap, the main parts are the externally supported electric generator 38 , the open web cradle 44 , the pile anchors 15 , the cradle docking support struts 34 , the docking pins 45 , the pile restraint caps 46 and the sloping topographical changes 26 .
FIGS. 16 and 17 shows the placement of the Turbine Blade Propeller 13 style 48 on the blade spindle 52 , connected to the end of the turbine blade/propeller shaft 29 , which powers an internally supported electric generator 12 . This arrangement could also be made with the externally supported electrical generator 38 . As the turbine blade/propeller shaft 29 can be utilized with both types of generators so can various types of water current driven rotational units be able to be placed on either of these generators by use of the turbine blade/propeller shaft 29 . The Turbine Blade Propeller 13 style 48 is perceived as an open weave bladed windmill type arrangement with surface added directional enhancers. The weave itself is unique and is comprised of structural non-corroding channels 49 that direct the water flow in an altered direction as it passes through and over the face of each channel 49 . This action gives the blades increased rotational force. The amount of open space between the individual channels is a consideration of: size of blades, rotational force required, structural stability, multiplicity and other engineering principles. To the front of this blade channel weave can be added further directional enhancers 50 . These enhancers add to the rotational output. Finally, each individual blade is positioned in relationship with it's neighboring blade much as the conventional windmill blades, both in blade pitch into the flowing current and individual blade shape overlap so that each component blade 51 , comprised of the channel weave 49 and the rotational enhancers 50 , also act as a homogenized single blade on a rotator to further add to the rotational force placed on the turbine blade/propeller. These blades 51 are large and slow moving, but exert large amounts of rotational torque on the turbine blade/propeller shaft 29 .
FIG. 17 is the front view of the Turbine Blade Propeller 13 style 48 and has in a rotational configuration eight individual blades 51 pitched and overlapped in order to maximize conversion to rotational movement. The blade composition has been discussed earlier, and is made up of a weave of non-corrosive channels 49 overlaid with rotational enhancers 50 set on the center-mounted spindle 52 that is mated to the turbine blade/propeller shaft 29 . The pre-manufactured concrete cradle 16 and anchoring piles 15 are shown as a gauge to relative size, the open web cradle 44 could have been depicted because of design interchangeability. To simplify the drawings, the concrete cradle 16 will continue to be used as part of the illustrations for the different types of turbine blade/propeller type units. The electric generator unit, either 12 or 38 , is hidden behind the turbine blade/propeller in this view. The exact size of the turbine blade/propeller may be larger or smaller than what is depicted, based on the engineering calculations required for optimum performance with the connected generators, either 12 or 38 , required rotational torque demands.
FIGS. 18 and 19 shows the placement of the Propeller Weave Rotational Unit 13 style 53 , on an internally supported electrical generator 12 . This arrangement is again made up of an open weave arrangement of channels 49 grouped in a turbine blade fashion. This composite is constructed in the fashion of overlapping and pitched blades 54 , while each blade captures a portion of the current's 17 kinetic energy, it also allows the remainder of the current 17 to pass through and affect the next blade 54 that is positioned offset and behind the blade in front. This multi-layering of blades 54 continues until the required rotational torque is applied to the center spindle 52 , which transfers this energy to the rotational shaft 29 , that then powers the attached electric generator, either 12 or 38 .
FIG. 19 is the front view of the Propeller Weave Rotational Unit 13 style 53 . It is visible that this unit is made up of three layers of four blades 54 that are constructed of the rotational weave channels 49 previously discussed. These blades 54 are formed in a square with radius corners shape. This shape provides the maximum rotational weave 49 surface area to the current 17 . The rotational weave 49 also allows the current's force to act correspondingly on the multiple layers of blades 54 , as previously discussed. This unique shape of the blade 54 also lends itself to be angled into the current and add to the rotational force exerted on the coupled shaft 29 . The Propeller Weave Rotational Unit 13 style 53 has been depicted in FIG. 18 and FIG. 19 , as three layers of four blades, but may be either more or less layers or blades, depending on the torque requirements of the electric generator to be powered.
FIG. 20 is a side view of The Box Blade Weave Propeller 13 style 55 . This is a more conventional propeller arrangement. The body of this style is made up of a weave of structural non-corroding channels 49 that again direct the water flow in a slightly altered direction as it passes through and over the face of the channels 49 . This reaction to the force of the current imparts a rotational force to the weave as a whole. This weave again is arranged in a blade type fashion. The blades are connected via a center spindle 52 to the rotational shaft 29 , which imparts rotational force to the attached electric generator, either 12 or 38 . In this arrangement the blades 56 , are protected by a circular cage arrangement 57 that also serves to direct the flow of the current 17 against the blades to increase the rotational force imparted on the system as a whole.
FIG. 21 is the front view of Box Blade Weave Propeller 13 style 55 . The circular cage 57 also protects the blades 57 from floating objects carried in the current 17 . The other items shown are as previously discussed: Pre-Manufactured concrete cradle 16 , anchor piles 15 , the blades 57 , the blade weave composition 49 , the spindle 52 , and the ocean current channel bottom 26 .
FIG. 22 is the side view of the Box Blade Solid Vane Propeller 13 style 58 . In this arrangement the blades 59 are constructed in a more conventional fashion using non-corroding material of a solid material. These blades are constructed in a fan type arrangement inside a similar circular cage 57 , connected to a center spindle 52 , and with the other corresponding parts as already discussed. This fan arrangement is drawn as having 16 blades, but may have more or less and be shaped differently based on the rotational torque required by the electric generator coupled to the shaft 29 .
FIG. 23 is the front view of the Box Blade Solid Vane Propeller 13 style 58 .
FIG. 24 is the side view of The Skeletal Spiral Turbine 13 style 60 . This rotational assembly is constructed in an increasing spiral form from the center point 61 toward the outside edges 62 . This spiral is angled to optimally direct the current toward the outer edges of the spiral thus turning this directed force of the ocean water current 17 into rotational movement. The spiral again is constructed of the directional channel weave 49 that is formed into shape by the support rods 63 and the support cables 64 . The support rods and cables 63 , 64 are constructed of non-corrosive materials chosen for their design composition. This skeletal spiral turbine is connected to the traditional rotational shaft 29 by the means of the center point 61 being attached to the rotational shaft 29 .
FIG. 25 is the front view of the Skeletal Spiral Turbine 60 . This view shows the spiral effect from the center point 61 , that is pointed toward the oncoming current 17 , toward the outside reinforced edges 62 . The current flow 17 is converted to rotational force that turns the rotational shaft 29 which powers the coupled generator, either 12 or 38 . The spiral is constructed of the weave of directional cannels 49 . To reinforce the spirals flat surfaces and keep them angled towards the ocean current 17 flow, an arrangement of support rods 63 and cables 64 have been employed. The skeletal nature of this turbine/propeller decreases the weight and allows for more surface area to be used, which equals more rotational torque for the same expenditure in materials.
FIG. 26 is the side view of the Multiple Three Blade Configuration 13 style 65 . This design is based on the common wind turbine blade design with the new feature of multiple additional blade sets. The additional sets of turbine blades captures more of the water current's 17 energy and by being used in multiple sets, slows down the rotational requirements of the system as a whole. Remember our goal is large slow moving rotational blades imposing large amounts of torque to the rotational shaft 29 . The blades 66 are constructed of non-corrosive materials and be shaped to impart rotational motion from a frontal current flow.
FIG. 27 is the front view of the Multiple Three Blade Configuration 13 style 65 . The internally supported electric generator 12 is visible behind the multiple blades 66 . The pre-manufactured concrete cradle 16 and the cradle piles 15 are also visible in the rear of this view.
A great deal of time has been spent looking at the propulsion (turbine blade/propeller 13 ), component for these electric generators 12 and 38 . Up to this invention, there has not been a need for a completely submerged rotational turbine blade/propeller 13 , unit to turn a completely immersed power-producing electric generator 12 and 38 . Further selection for the final type and style of the turbine blade/propeller 13 units are made based on specific conditions for each electric generator 12 or 38 placed within each Hydro-Electric Farm.
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An underwater hydro-electric farm comprising a plurality of electrical generator assemblies arranged in an array on a bottom surface of a body of water within an ocean current path to take generate power from a kinetic energy caused by the flow of the underwater current. Each assembly is installed in a cradle, which is anchored with a pile driven system to the bottom surface. Each assembly is a modular system allowing for easy swapping out of an assembly under water. Generated power is transmitted to a land based facility directly to or through an intermediate transfer station. Generator portion may have internally or externally supported field windings. Various configurations of propellers may be used, some with channels or solid vanes and another being a spiral shaped propeller. All water exposed surfaces of the generator and propeller portions are coated with a non-conductive, heat dissipating, anti-fouling and water specific protective coating.
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BACKGROUND OF THE INVENTION
This invention is a method of shop assembly for shipment and of field erection of large and medium size boiler furnace wall components forming the furnace envelope for boilers that are larger than the totally shop-assembled unit.
In present-day practice wall panels are generally fabricated in the shop and consist of a membrane type construction. This construction consists of flat wall sections composed of panels of single rows of tubes on centers wider than a tube diameter, connected by means of a membrane or steel bar welded to the tube on its centerline. The membrane panels, up to shipable widths and shipable lengths, are then pack-bent where required and shipped to the installation site. Field erection then comprises lifting and welding the panels together to form the furnace envelope and attaching buckstays, doors, insulation, lagging and other appurtenances.
SUMMARY OF THE INVENTION
The invention comprises furnishing and field erecting shop assembled finished wall components including membraned tube panels, buckstays, doors, insulation, lagging and other appurtenances, resulting in improved quality of product and reduction in cost and length of field construction programs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic partial side view of a representative boiler unit.
FIG. 2 is a schematic side view of a representative rear wall panel.
FIG. 3 is a schematic rear view of a representative rear wall panel.
FIG. 4 is an enlarged side view taken along the lines 4--4 of FIG. 3.
FIG. 5 is an enlarged view taken along the lines 5--5 of FIG. 4.
FIG. 6 is a schematic view of a membrane wall construction.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, shown is a schematic side view of a boiler unit 10. The unit depicted is a mass burning refuse boiler but it should be understood that the methods and principles of the invention can be applied to designs for any type of firing. The furnace envelope includes water-cooled membraned front wall 12, rear wall 14, side walls 16, extension furnace side walls 18 and boiler side walls 20. Also shown are furnace outlet screen 24 and horizontal buckstays 22.
FIGS. 2 and 3 show rear wall modules 14 with horizontal buckstays 22 and temporary beams 26 attached at the job site. The modules are lifted by cables 28 attached to beams 26 to a vertical position for weld attachment to adjacent panels or modules.
FIG. 4 is an enlarged view of temporary and reusable beams 26 attached to buckstay 22 bearing against tie bar 30 and supporting membrane wall tubes 32. Insulation 34 and metal lagging, shown in FIG. 6, have been applied in the shop prior to shipment.
FIG. 5 is a detail of the method of supporting beam 26 from buckstays 22 by temporary bolts 36.
FIG. 6 shows a typical membrane wall construction comprising tubes 32 joined together by membrane bars 38. The walls thus formed are gastight and require no inner casing to contain the products of combustion. Insulation 34 is provided on the outer side of the wall, and metal lagging 40 covers the insulation.
Under present-day procedures, membrane tube wall panels will deflect or bend when lifted from a horizontal to a vertical position in erecting a unit. Panels are normally raised from quarter or third points along the panel length to minimize deflection. Deflection of the metallic panel is within elastic limits and the panel is undamaged.
The modular furnace wall panel, as conceived by the inventors, includes all parts, doors, buckstays, insulation pins, thermal barriers, insulation, lagging and any other appurtenances constituting a finished wall component as shipped to the job site. In order to handle modular or finished wall components without damage, deflection or bending must be restricted below allowable values for unfinished panels. Horizontal buckstays 22 restrain deflection in the horizontal direction and temporary beams 26 provide restraint in the vertical direction. Deflection is further limited by lifting the module from structural cross points.
While in accordance with the provisions of the statutes there is illustrated and described herein a specific embodiment of the invention, those skilled in the art will understand that changes may be made in the form of the invention covered by the claim and that certain features of the invention may sometimes be used to advantage without a corresponding use of the other features.
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Completely assembled wall modules including membraned tube panels, buckstays, doors, insulation and lagging for field-assembled boiler units are shipped to the installation site for field erection of the boiler unit.
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ORIGIN OF THE INVENTION
This invention was made with Government support under NAS8-36200 awarded by NASA. The Government has certain rights in this invention.
TECHNICAL FIELD
The invention relates to a stereo optical system for locating a visible indicia on a workpiece and for producing output signals which may be processed for the actuation of an industrial robotic device. The robotic device may be utilized to operate many types of industrial equipment, such as welders, x-ray machines, adhesive applicators, riveting machines, and other similar devices.
BACKGROUND OF THE INVENTION
The invention will be described for illustration in the context of a robotic arc-welding, seam tracking system. However, the system is equally effective for guidance and control of any type of industrial robot which is required to locate and/or track indicia on a workpiece. The indicia may be in the form of a dot, a hole, a line, a groove, a seam or a similarly indicated path or point.
The use of optically controlled seam trackers in conjunction with robotic welders has been extensive in recent years. Examples of such systems are found in the following U.S. Patents: Taft et al U.S. Pat. No. 4,833,381 issued May 23, 1989; Gordon U.S. Pat. No. 4,831,233 issued May 16, 1989; Richardson U.S. Pat. No. 4,737,614 issued Apr. 12, 1988; Shibata et al U.S. Pat. No. 4,667,082 issued May 19, 1987; Polick et al U.S. Pat. No. 4,590,356 issued May 20, 1986; Smith et al U.S. Pat. No. 4,567,348 issued Jan. 28, 1986; and Richardson U.S. Pat. No. 4,501,950 issued Feb. 26, 1985.
Review of previous systems reveals critical shortcomings in the systems capabilities to provide an effective and inexpensive means of providing three dimensional guidance for robotic welding apparatus. It will be noted that these devices are not capable of providing a usable 3-D optical image of the seam unless the seam is grooved or spaced.
By use of the stereo vision concept with a single camera the present invention provides features not possible with the above listed or any known prior art. In addition to the ability of the present invention to track accurately, the stereo vision concept permits precise quantitative three dimensional control of an industrial robot. Use of a single camera, rather than two cameras, not only halves the camera costs but greatly simplifies the system electronics and reduces the size of the program software.
SUMMARY OF THE INVENTION
The present invention provides an improved optical system for the generation of basic electrical signals which are supplied to a computerized processing complex for the operation of industrial robots. The system includes a stereo mirror arrangement for the projection of views from opposite sides of a visible indicia formed on a workpiece. The views are projected onto halves of the retina of a single camera. The camera retina is of the CCD (charge-coupled-device) type and is therefore capable of providing signals in response to the image projected thereupon. These signals may then be processed for control of industrial robots or similar devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of the invention showing in particular the arrangement of optical components and the resultant light paths.
FIG. 2 is a frontal view illustrating the arrangement of the mirrors and the laser illuminators of the invention.
FIG. 3 is a diagrammatic view of the invention illustrating its use with a robotic welding machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 1, this stereo guidance system includes a housing 14, which encloses mirrors 9L, 9R, 10L and 10R, a camera 11, a light filter 11a, a lens 11b and a retina 12. The retina 12 of the camera 11 is of the CCD (charge-coupled-device) type which converts the image formed thereon into electrical signals which are transmitted by a cable 11d to a computer, processor complex 20, for operation of industrial type robots 22.
The mirrors 9L, 9R, 10L and 10R include the alphabetic left and right hand designations to simplify the description of the optical paths and the configuration of the system. Further, it will be noted that the mirrors 9L and 9R are located near the outer portion of the system and will be referred to as peripheral mirrors while the inwardly located mirrors 10R and 10L will be referred to as center mirrors.
As illustrated, the peripheral mirrors 9L and 9R direct light to the central mirrors 10L and 10R which in turn direct the light into the camera lens 11b. Because of the spaced apart, or stereoscopic locations of the left and right mirrors, two separate images will be impinged upon the retina 12 of the camera. One image is impinged upon each of the left and right portions 12L and 12R of the retina 12.
A workpiece 5 includes two metal portions 5L and 5R which are intended to be welded at a seam 6. It will be noted that seam 6 forms an indicia 7 which defines a line which is the only visible portion of the seam as seen by the system optics.
The indicia or visible line 7 is located within a simultaneous viewing polygon 8 which is defined by extreme undeviated rays 1, 2, 3, and 4. Light reflected to the left by the apparent line 7 will travel along the imaginary corridor bounded by rays 2 and 4, striking in turn mirrors 9L and 10L, filter 11a, lens 11b and will finally illuminate a line of pixels (image 12L) on the right half of the CCD array retina 12. Similarly light from the indicia 7 which is scattered in a rightward direction will travel along the imaginary corridor bounded by rays 1 and 3 and strike in turn mirrors 9R and 10R, pass through the filter 11a and the lens 11b, and will form the image 12R on the left half of the CCD array retina. It is understood that indicia of any type whether it be a hole, a dot, a line, a seam, or any visible marking which is located within the simultaneous viewing polygon 8 will be quantitatively locatable in three dimensions by the CCD retina.
Initial set-up adjustments of the system include a precise predetermined orientation of the workpiece to the system. This orientation is based upon a mathematical model of the relative positions of the optical components of the system. Thus, after such orientation it will be clear that indicia on the workpiece may be precisely located and that relative movement between indicia on the workpiece and the stereo system will be reproduce in the images which illuminate lines of pixels on the retina 12. The retina, being of the CCD array configuration, produces basic signals which, when received by a properly programmed computer, processor complex 20, may be processed to control the movement and operation of various types of industrial robots 22. The CCD array provides signals which vary in accordance with the intensity of the light which strikes it in any given area. This permits the system to react precisely to the varying shades of light of an image projected upon the array. This feature is referred to as "gray-scale" processing. Such computer and processing equipment is well known in the art and is therefore not illustrated in detail in the drawings. Use of cameras having a CCD or similar capability in conjunction with a computer, processor complex for operation of industrial robots is illustrated in Smith et al U.S. Pat. No. 4,567,348 issued Jan. 28, 1986 which is cited as related art earlier in the application.
FIG. 2 is a frontal view of the stereo vision system which illustrates the location of laser diode illuminators 16 through 19 relative to the peripheral mirrors 9L and 9R. The numerals 16 and 17 indicate linear laser diode illuminators mounted above the peripheral mirrors while global illuminators 18 and 19 are located outwardly from the mirrors. The global laser diode illuminators 18 and 19 provide general illumination of the workpiece while the linear laser diode illuminators 16 and 17 provide a structured stripe of intense light which is precisely directed to the indicia to be located or tracked.
FIG. 3 is a diagrammatic view of the arrangement of elements of the stereo vision system illustrated as applied to a robotic welding system. As an additional important feature of the invention, it will be noted that a welding wire 13, also illustrated in FIG. 1, is positioned between the peripheral mirrors of the system whereby the images received on the peripheral mirrors are not impeded by the wire. A wire feed positioner 22 is attached to a welding torch assembly 24. The torch 24 ejects a plasma stream 26 to effect the welding process.
In operation, the stereo vision system collects visual information necessary to locate and track indicia on the workpiece 5. This indicia may be in the form of a visible line, a marked point, a hole, or as illustrated, the line or indicia 7 as formed by seam 6 between the pieces of metal 5L and 5R to be welded together. This collection of visible information is accomplished by forming two images 12L and 12R of the visible indicia 7 on the CCD array or retina 12. This information (image 12L and image 12R) is combined with a precise mathematical model including the internal dimensions of the optical elements of the stereo vision sensor. The computer processor complex 20, appropriately programmed, will then deduce the precise location in space of indicia 7 with respect to the optics of the system. Knowing the location of the indicia 7 allows the computer to generate appropriate commands to a torch positioning device 22, keeping the torch aligned with, and properly spaced from, the indicia 7 during the welding process.
Initially the pieces to be welded, 5L and 5R, are positioned appropriately with respect to the optics of the system, that is, their visible common boundary, which the system views as indicia 7, lies within the simultaneous viewing polygon 8, defined approximately by the extreme undeviated rays 1, 2, 3, and 4. Thus it will be apparent that light reflected to the left by the apparent line or indicia 7 will travel along the imaginary corridor bounded by rays 2 and 4, striking in turn mirrors 9L and 10L, pass through filter 11a, and lens 11b, and will finally illuminate a line of pixels (image 12L of indicia 7) on the right half of the CCD array 12. Similarly, light from the visible part of the seam 7 which is scattered in a rightward direction will travel along the imaginary corridor bounded by rays 1 and 3 and strike in turn mirror 9R and mirror 10R, pass through filter 11a and lens 11b, and will form an image 12R of indicia 7 upon the left half of retina 12. Impingement of the images of the indicia upon the half portions 12L and 12R of the retina 12 will illuminate a line of pixels in the central area of each half of the retina. It will be seen that any change in the distance between the indicia 7 and the optics systems will be instantly sensed as a change in distance between the illuminated lines on the retina 12. Thus it will be appreciated that the stereo feature of this system provides the ability of the system to instantly react not only to length and width movements, but also to the very important third dimension of depth or distance. This feature is particularly useful in voltage controlled welding systems wherein the distance between the welding head and the workpiece is constantly changing to effect the best possible welding process. As previously mentioned the CCD type array included in retina 12 will react to images and image changes by production of output signals which are processed to effect guidance and control of various types of industrial robots 22.
While certain preferred embodiments of the present invention have been disclosed in detail, it is to be understood that various modifications may be adapted without departing from the spirit of the invention or scope of the following claims.
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A device for the generation of basic electrical signals which are supplied to a computerized processing complex for the operation of industrial robots. The system includes a stereo mirror arrangement for the projection of views from opposite sides of a visible indicia formed on a workpiece. The views are projected onto independent halves of the retina of a single camera. The camera retina is of the CCD (charge-coupled-device) type and is therefore capable of providing signals in response to the image projected thereupon. These signals are then processed for control of industrial robots or similar devices.
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This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/751,525, filed on Dec. 19, 2005. The teachings of U.S. Provisional Patent Application Ser. No. 60/751,525 are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Adhesives are utilized in a wide array of applications including packaging, in manufacturing consumer and industrial products, and in household applications. The type of adhesive needed is dependent upon the requirements of the application and the substrates to which it will be applied. Accordingly, countless different types of adhesive compositions have been developed to meet the demands of the applications in which they will be used. It is, of course, critical to select an adhesive that meets all of the physical and chemical requirements of a given application.
Adhesives are sometimes applied to roofing shingles to secure them to the roof structure to which they are being applied. The adhesive can be the sole means for affixing the roofing shingles to the structure or the adhesive can be used in conjunction with roofing nails or other mechanical means for affixing the shingles to the substrate. U.S. Pat. No. 6,753,362 described a cold bond adhesive composition that produces a strong bond between a polymeric capping membrane used in a roofing application and a roofing substrate. This composition is comprised of a homogeneous 60 to 75% solids mixture of (a) between about 0.5 weight percent and about 15 weight percent of a thermosetting styrene/isoprene/styrene block polymer containing up to 90% styrene; (b) between about 13 weight percent and about 30 weight percent of a aromatic hydrocarbon solvent containing from about 5 weight percent to about 20 weight percent aliphatic hydrocarbon; (c) between about 20 weight percent and about 70 weight percent a non-blown asphalt optionally containing a minor amount of blown asphalt; (d) between about 1 weight percent and about 10 weight percent of a metal silicate and (e) between about 0.1 weight percent and about 5 weight percent of a C 6 to C 16 alkoxyalkyl amine substituted ester of a C 2 to C 12 carboxylic acid as a surfactant.
In some cases self seal adhesive compositions are applied to the underside of roofing shingles and covered with a release tape at the factory where they are manufactured. This allows for the adhesive to be applied to the roofing shingles under the controlled environment of the factory which offers the advantage of consistency and reduced risk of contamination. The release tape keeps the adhesive from prematurely sticking to surfaces in an undesired manner during storage and transportation. The release tape can be removed from the underside of the roofing shingles at the site where it is being applied as a roof covering shortly before it is used. This can be done by simply pulling the release tape from the roofing shingle to expose the adhesive. Roofing shingles of this type are described by U.S. Pat. No. 6,813,866 and U.S. Pat. No. 6,895,724. The adhesive utilized in such applications is typically an asphalt composition that has been modified with a block copolymer, such as a styrene-butadiene-styrene triblock polymer, a styrene-isobutylene-styrene triblock polymer, or a styrene-ethylene-butadiene-styrene block polymer.
The utilization of block copolymers in such asphalt based adhesive compositions substantially increases cost. Polymer modified asphalts that are used in adhesive applications are also susceptible to phase separation which in turn can lead to instability over time. Accordingly, a lower cost self seal adhesive that does not phase separate and which possesses the characteristics needed for adhering asphalt based roofing shingles to roof structures is in demand.
SUMMARY OF THE INVENTION
This invention is based upon the discovery that the solvent extracted aromatic cut of heavy vacuum gas oil can be oxidized to produce an adhesive composition that has all the needed attributes of a self seal adhesive for asphalt roofing shingles. This self seal adhesive composition offers numerous benefits and advantages over conventional self seal adhesives for roofing applications. For instance, it does not require any volatile organic solvents and is accordingly environmentally friendly. The self seal adhesive composition of this invention does not contain any asphalt or polymers and will not phase separate. Thus, it offers excellent long term stability. Additionally, the self seal adhesive composition of this invention is made by the simple oxidation of the solvent extracted aromatic cut of heavy vacuum gas oil and is accordingly relatively inexpensive.
The present invention more specifically discloses an oxidized aromatic viscoelastic resin wherein said resin is comprised of an oxidized solvent extracted aromatic cut of heavy vacuum gas oil.
The subject invention also reveals a self seal adhesive composition made by a process which comprises oxidizing a solvent extracted aromatic cut of heavy vacuum gas oil. The oxidation is typically done by air blowing at a temperature which is within the range of 400° F. (204° C.) to 550° F. (288° C.). The air blowing is normally conducted until the oxidized solvent extracted aromatic cut of heavy vacuum gas oil has a softening point which is within the range of 170° F. (77° C.) to 250° F. (121° C.). The air blowing will preferably be conducted until a softening point within the range of 170° F. (77° C.) to 200° F. (93° C.) is attained.
The present invention further discloses an asphaltic roofing shingle which is comprised of a back surface and an exposure surface, wherein the asphaltic roofing shingle has a self seal adhesive on the back surface or the exposure surface, and wherein the self seal adhesive is comprised of an oxidized solvent extracted aromatic cut of heavy vacuum gas oil. The self adhesive is typically on the back surface of the roofing shingle and the self seal adhesive is generally covered with a release tape to facilitate storage and transportation of the roofing shingles.
DETAILED DESCRIPTION OF THE INVENTION
The first step in refining crude oil typically involves distilling it under atmospheric pressure. This atmospheric distillation step typically separates the light hydrocarbon constituents of the crude oil stream having boiling points of below about 400° C. (204° C.) from the heavy hydrocarbon constituents that have boiling points of higher than about 400° C. (204° C.). The light hydrocarbon streams recovered from the atmospheric distillation step normally include (1) C 1 to C 4 hydrocarbon gases, such as methane, ethane, ethylene, propane, butane, 1-butene, 1,3-butadiene, and similar gases, (2) light straight run gasoline, (3) heavy straight run naphtha, (4) kerosene, and (5) light atmospheric gas oil. The heavy hydrocarbon constituents that remain are known as the atmospheric distillation unit bottoms. These distillation unit bottoms are then subjected to a vacuum distillation step which separates this mixture of heavy hydrocarbons into a light vacuum gas oil stream, a heavy vacuum gas oil stream, asphalts, and vacuum distillation residue.
The heavy vacuum gas oil is a complex mixture of hydrocarbons that typically contain from about 25 carbon atoms to about 45 carbon atoms and which has a boiling point within the range of about 650° F. (343° C.) to about 1050° F. (566° C.). The heavy vacuum gas oil is characterized by containing less than about 0.3 weight percent asphaltenes. The heavy vacuum gas oil will typically contain less than 0.2 weight percent asphaltenes and will more typically contain less than 0.1 weight percent asphaltenes. However, the heavy vacuum gas oil should be distinguished from the stream of heavy material which is removed near the bottom of the vacuum gas column which is referred to as slop wax. The heavy vacuum gas oil contains both an aromatic component and an aliphatic component. The aromatic component can be separated from the aliphatic component by solvent extraction.
The aromatic cut recovered by solvent extraction of the heavy vacuum gas oil stream is an opaque resinous material that is used commercially as a viscosity builder for metal working applications. This solvent extracted aromatic cut of heavy vacuum gas oil typically has a flash point which is within the range of about 590° F. (310° C.) to about 650° F. (343° C.) and is identified by C.A.S. No. 8052-42-4. It is available commercially from The American Refining Group, Inc. as Kendex® 0897 resin.
In making the self seal adhesive composition of this invention the solvent extracted aromatic cut of heavy vacuum gas oil is oxidized by exposing it to an oxygen containing environment at an elevated temperature. This can be accomplished by utilizing an air blowing procedure. In such an air blowing technique the solvent extracted aromatic cut of heavy vacuum gas oil is heated to a temperature which is within the range of 400° F. (204° C.) to 550° F. (288° C.) and an oxygen containing gas is blown through it. This air blowing step will preferably be conducted at a temperature which is within the range of 425° F. (218° C.) to 525° F. (274° C.) and will most preferably be conducted at a temperature which is within the range of 450° F. (232° C.) to 500° F. (260° C.). This air blowing step will typically take about 4 hours to about 12 hours and will more typically take about 8 hours to about 10 hours. However, the air blowing step will be conducted for a period of time that is sufficient to attain a softening point within the range of 170° F. (77° C.) to 250° F. (121° C.). The solvent extracted aromatic cut of heavy vacuum gas oil will typically be air blown until a softening point within the range of 170° F. (77° C.) to 200° F. (93° C.) is attained. The oxidized solvent extracted aromatic cut of heavy vacuum gas oil is at least 95% soluble in normal-heptane and is preferably at least 98% soluble in normal-heptane. The oxidized solvent extracted aromatic cut of heavy vacuum gas oil also exhibits ultraviolet fluorescence. Furthermore, the oxidized solvent extracted aromatic cut of heavy vacuum gas oil contains carbonyl functionality, such as ketone moieties.
The oxygen containing gas (oxidizing gas) is typically air. The air can contain moisture and can optionally be enriched to contain a higher level of oxygen. Chlorine enriched air or pure oxygen can also be utilized in the air blowing step. Oxidation can be performed either with or without a conventional air blowing catalyst.
The oxidized solvent extracted aromatic cut of heavy vacuum gas oil can optionally be blended with about 5 weight percent to about 40 weight percent of a filler in making the self seal adhesive composition. The filler will typically be employed at a level which is within the range of 10 weight percent to 30 weight percent. The filler will typically be a mineral filler, such as limestone, clay, talc, fly ash, volcanic ash, graphite, carbon black, silica, or a mixture of such mineral fillers. Polymeric fillers, such as polyisobutylene, can also be used. However, the self seal adhesive compositions of this invention will normally be void of polymeric materials, such as block copolymers. Accordingly, the self seal adhesive composition will typically be void of styrene-butadiene-styrene triblock polymers. It is also typically void of rubber cements, such as solutions of styrene-butadiene rubber. The adhesive compositions of this invention will also be typically of free of ethylene-vinyl acetate, modified acrylics, and organic solvents.
The self seal adhesive compositions of this invention can be applied to asphalt roofing shingles in the conventional manner. The self seal adhesive can either be applied to the exposure surface of the roofing shingle or to the back of the shingles. The adhesive will typically be applied to the back of the roofing shingles which will allow the shingles to adhere directly to a wooden roofing surface, a roofing underlayment, or a roof deck that already has a roofing material installed on it. In other words, the self seal adhesive of this invention will form a strong bond to wood, roofing underlayment materials, and the exposure surface of preexisting roofs. Accordingly, it can be used in new construction or in the installation of a new roof over a previously installed roofing material.
The self seal adhesive composition will typically be applied to the roofing shingles as part of the process used in manufacturing them. In such cases, the adhesive on the roofing shingles will be covered with a release tape so that the roofing shingles do not have any areas of exposed adhesive on their surface. Covering the adhesive with release tape makes it feasible to store and transport the roofing shingles through chains of distribution and ultimately to the site of application. The release tape is normally a polymeric film of a polyester or a polyolefin, such as polyethylene or polypropylene, which is treated with a silicon compound on the side that will be in contact with the adhesive. The release tape is typically from about 20 to about 100 microns thick and is preferably from 40 to 80 microns thick. The silicon compound prevents the adhesive from forming a strong bond to the release tape and allows for the release tape to be removed before the roofing shingle is applied to the desired surface.
The self seal adhesives of this invention can be used in conjunction with virtually any type of asphalt roofing shingles. For instance, the self seal adhesives of this invention can be used as a direct replacement for the self seal adhesives that are used in manufacturing self seal roofing shingles that are known in the art using known techniques. Such roofing shingles are described in detail in U.S. Pat. No. 6,696,125, U.S. Pat. No. 6,813,866 and U.S. Pat. No. 6,895,724. The teachings of U.S. Pat. No. 6,696,125, U.S. Pat. No. 6,813,866 and U.S. Pat. No. 6,895,724 are incorporated herein by reference with respect to describing the types of shingles that can be used in conjunction with the self seal adhesives of this invention and techniques that can be used to manufacture such shingles.
This invention is illustrated by the following examples that are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.
Example
In this experiment a solvent extracted aromatic cut of heavy vacuum gas oil was oxidized by air blowing. The solvent extracted aromatic cut of heavy vacuum gas oil used was Kendex® 0897 resin (C.A.S. 8082-42-4). It was characterized by having a viscosity at 100° C. of about 47.5 cSt, a flash point of about 590° F. (310° C.), and a pour point of about 9° C.
In the procedure used, the solvent extracted aromatic cut of heavy vacuum gas oil was heated to a temperature of 500° C. and air was blown through it for about 9 hours while it was maintained at the temperature of 500° C. The air being blown through the solvent extracted aromatic cut of heavy vacuum gas oil provided sufficient agitation and additional mixing or stirring was not required. Over the 9 hour period the softening point of the solvent extracted aromatic cut of heavy vacuum gas oil increased as it oxidized until it reached a final softening point of 205° C.
The oxidized solvent extracted aromatic cut of heavy vacuum gas oil produced exhibited excellent adhesion to wood and to asphalt roofing shingles. It can be applied to the back of asphalt roofing shingles and covered with release tape. These shingles can then be applied to wooden roofs or over the top preexisting roofing shingles. In either case the self seal adhesive meets all of the physical and chemical requirements needed in such applications.
While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention.
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It has been unexpectedly found that the solvent extracted aromatic cut of heavy vacuum gas oil can be oxidized to produce an adhesive composition that has all the needed attributes of a self seal adhesive for asphalt roofing shingles. This adhesive composition does not require any volatile organic solvents and is accordingly environmentally friendly. It does not contain any asphalt or polymers and will not phase separate. Thus, it offers excellent long term stability. Additionally, it is made by the simple oxidation of the solvent extracted aromatic cut of heavy vacuum gas oil and is accordingly relatively inexpensive. The subject invention more specifically reveals an asphaltic roofing shingle comprising a back surface and an exposure surface, wherein the back surface is covered with an oxidized solvent extracted aromatic cut of heavy vacuum gas oil.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a compact lens barrel mechanism suitable for an optical lens system having relatively shiftable lens groups and more particularly to a lens barrel mechanism for relatively shifting the lens group in a linear movement along the optical axis to accomplish two or more modes of operation.
2. Description of the Prior Art
The prior art is quite familiar with various forms of lens barrel mechanism for mechanically shifting relative groups of lens. Quite frequently, the lens barrel mechanisms will rotate the lens groups in a spiral or helicoidal movement along the optical axis. As can be appreciated, lenses moved in this fashion must be carefully centered and aligned to maintain a correct position on the optical axis regardless of the relative movement. For example, U.S. Pat. No. 3,904,275 is of interest in showing a lens barrel mechanism for moving a front and rear lens group.
Additionally, it is known that a soft focus condition can improve certain pictures.
The prior art is still striving to optimize the design of lenses with the most compact lens barrel mechanism that is economically and physically capable of being utilized. The consumer market is demanding light and more compact lenses at commercially acceptable prices. Accordingly, there is still a need in the prior art to optimize a lens barrel mechanism within these parameters.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a compact lens barrel mechanism for a novel lens system having at least three separate lens groups. The first lens group need only be shifted relative to the second and third lens groups for varying the air space between the first and second lens group in a first mode of operation. The third lens group is required to be shifted at a different ratio from that of the first and second lens group in a second mode of operation.
Another object of the present invention is to provide a compact lens barrel mechanism which can provide the above mentioned shifting of the lens groups without any rotation of the lens groups about the optical axis. That is, it is desirable for the lens groups to linearly move along the optical axis without using the heretofore conventional rotation of the individual lens elements. Another advantage of the present invention is to simplify the diaphragm control and to prevent any disturbance of the mechanical connection of the diaphragm mechanism with the control mechanism located within the camera body.
Still another advantage of the present invention is to prevent any eccentric dislocation between the lens groups resulting from any relative rotation of the lens group during their movement along the optical axis. Finally, an additional advantage of the present invention is to permit the attachment of polarization filters and/or rectangular hoods to the first lens group and not to rotate them about the optical axis during the different modes of operation of the lens system.
The above advantages can be realized by providing a compact optical lens barrel mechanism to accommodate relatively shiftable lens groups including a fixed cylinder; a transitional cylinder journalled in the fixed cylinder for relative circulate movement, and a plurality of individual lens element mounting members having appropriate linear alignment elements for coacting with other appropriately positioned linear alignment elements within the lens barrel mechanism. Rotational means are provided to permit the selective movement of predetermined mounting members to provide both a focusing and soft focus mode of operation.
The objects and features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one example of a variable soft focus lens system that can be mounted in the lens barrel mechanism of the present invention; and
FIGS. 2, 3 and 4 are respective half cross-sectional views of an embodiment of the present invention shown in various operational modes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is provided to enable any person skilled in the optical art to make and use the invention and sets forth the best mode contemplated by the inventor in carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a compact lens barrel mechanism that can be manufactured in a relatively economical manner. The illustrated embodiment of the present invention is specifically advantageous for use with a variable soft focus lens system such as that described in U.S. Pat. No. 4,124,276 issued Nov. 7, 1978 for AN IMPROVED SOFT FOCUS LENS SYSTEM and assigned to the same assignee of the present invention. The disclosure of that application, although not essential for an understanding of the present invention, is hereby incorporated by reference to facilitate a greater understanding of the advantages of the present invention.
Referring to the schematic view of FIG. 1, a variable soft focus lens system of the type disclosed in the U.S. Pat. No. 4,124,276 is disclosed. As can be seen from FIG. 1, the lens system is divided into lens groups A and B with a variable air space dB separating them. Any variance of that air space dB, for example by widening or narrowing the air space will effect the amount of spherical aberration that is introduced into the final image, thus, the transmitted image can have only that amount of spherical aberration that is within the tolerances of a normal photographic condition to provide a sharp image or it can have any subjective amount of spherical aberration to provide a soft focus condition that is sometimes highly desirable in portrait and other photographs.
The lens group A is further divided into a pair of sub lens groups A1 and A2 having a variable air space dA separating them. This air space dA can be varied during a focusing mode of operation as will be described subsequently. To optimize the optical design, it is generally preferable that the subgroup A1 will include the diaphragm.
During a first mode of operation such as focusing, the subgroup A2 and the lens group B are maintained stationary while the subgroup A1 is shifted along the optical axis to thereby vary the width of the air space dA.
In the second mode of operation, a variable amount of spherical aberration can be introduced into the transmitted image by having the lens group A (with the air space dA maintained constant) and the lens group B moved at different ratios along the optical axis to thereby vary the air space dB. Both the lens groups A and B are moved in this mode of operation also to vary the air space dB to provide a compensation for any deviation of the image plane from the focal plane which would otherwise result from simply varying the air space dB.
Accordingly, by this movement of the lens groups A and B, the focus condition achieved by the setting of the air space dA is accurately maintained during the shifting from a normal sharp photographic condition to various soft focus conditions. As can be readily appreciated, soft focus photography is easily achieved in the above described lens system of FIG. 1. Since the lens system can be set into a normal sharp photography condition, the focusing operation can be achieved as easily as in the case of a normal lens system. After the focusing operation is completed, it is easy to shift from the normal photography condition to a desired soft focus condition without losing the focus condition desired. The lens system, accordingly, eliminates the problems generally associated with focusing for soft focus photography.
Referring to FIG. 2, an embodiment of the present invention is disclosed in a cross-sectional view to advantageously disclose the relative movement of the lens group required in the soft focus condition lens system. In FIG. 2, a first lens group 1 includes a diaphragm while the second lens group 2 and third lens group 3 are simply shown symbolically and actually correspond to the subgroup A1, subgroup A2 and lens group B shown in FIG. 1. A first lens mounting member or lens barrel 4, mounts a predetermined number of lens elements and provides a helical formation or external thread 4a over a portion of its exterior peripheral surface. The lens barrel 4 includes a thick wall portion on its inner periphery to support a diaphragm support ring 15 and a diaphragm operator ring 15a which is rotatively mounted on the diaphragm support ring 15 in a marginal position. An annular lens holding portion 4d projecting rearward along the direction of the optical axis from the inner peripheral wall of the first lens barrel 4 includes an annular elongated opening 4b. The purpose of this opening 4b, is to permit a follower pin 20 to have access to the diaphragm operator ring 15a. Thus, the follower pin 20 can extend through an elongated opening 4b and can rotate the diaphragm operator ring 15a without interference. Although not shown in the drawing for purposes of simplicity, the diaphragm, as is conventionally known, is interposed between the diaphragm support ring 15 and the diaphragm operator ring 15a. The diaphragm is pivotally supported by one of the rings and associated with the other ring through a conventional pin-cam slot arrangement so that the diaphragm setting will be governed by the rotation of the follower pin. The lens retaining portion 4d of the first lens barrel 4, is actually manufactured independently of the barrel body 4 and joined during assembly. However, for ease of illustration in the drawing it is simply shown as a one piece member with the barrel body 4.
A second lens mounting member or lens barrel 5 is loosely fitted over a rear portion of the first lens group 4 and carries a second lens group 2 which is rigidly mounted on its interface. The second lens barrel 5 includes an annularly elongated opening 5e to permit the passage of the diaphragm follower pin 20. The inner peripheral face of the second lens barrel 5 is formed with a longitudinally extending linear slot 5d that is parallel with the optical axis. A follower key 13 is connected to and radially extends from the end face of the first lens barrel 4 to engage the linear slot 5d. This arrangement prevents the first lens barrel 4 and the second lens barrel 5, from any relative rotation while still permitting a linear displacement. The outer peripheral side face of the second lens barrel 5 includes an annular ring having both an external thread 5a and a longitudinally extending linear slot 5c extending parallel with the optical axis. A smaller diameter portion of the second lens barrel also carries an external thread 5b for interfacing with a focusing ring to be described subsequently. A third lens mounting member or third lens barrel 6 mounts a predetermined number of lens elements forming a third lens group 3. The third lens barrel 6 also includes an annularly elongated opening 6a to again permit the continued passage of the diaphragm follower pin 20 parallel to the optical axis. A single guide follower pin 18 is mounted on the outer periphery of the third lens barrel 6 to provide a sliding linear movement to the third lens barrel 6.
A stationary mounting cylinder 7 which forms part of the exterior housing is connected or connectable with a camera body (not shown). The mounting cylinder 7 includes a first and second linear alignment element. One of the linear alignment elements is a guide slot 7a extending along its inner peripheral wall. A soft focus control ring 11 and the diaphragm ring 12 are mounted on the exterior of the stationary cylinder 7 and are rotatable thereabout in appropriate grooves. An index ring 8 is secured to and forms part of the forward end of the stationary cylinder 7. It is connected to the stationary cylinder 7 by means of a rivet 22 and has a forward end of a thick wall formation 8a. A cantilevered key 14, which forms the second linear alignment element, is rigidly secured to the forward end formation 8a and extends parallel to the optical axis. The cantilevered key 14 engages the longitudinal linear slot 5c on the second lens barrel 5. This arrangement prevents relative rotation of the second lens barrel 5 with respect to the stationary cylinder 7 about the optical axis.
A translational or outer cylinder 9 is journalled within the stationary mounting cylinder 7 to provide only relative circulate movement. The cylinder 9 is positioned between the thick wall portion 8a and a shoulder or land portion 7b formed on the rear interface of the stationary cylinder 7. The cam like head opening 9b is cut into the inner peripheral wall and forms a helical slot. The follower guide pin 18 is mounted on the third lens barrel 6 and extends into and through the cam like opening 9b to engage the linear alignment slot 7a on the stationary cylinder 7. A forward inner face of the outer cylinder 9 has an internally threaded portion 9a that engages the externally threaded portion 5a of the second lens barrel 5 to form a helicoid.
Extending forward of and loosely fitted over the index ring 8 of the stationary cylinder 7 is a distance or focus adjusting ring 10. The inner face of this ring 10 has internal threads 10a and 10b. The internal thread 10a meshes with the external thread 4a of the first lens barrel 4 to form a first helicoid, while the internal thread 10b thereof is in mesh with the external thread 5b of the second lens barrel to form a second helicoid. The third helicoid is formed between the threaded portion 5a of the second lens barrel 5 and the internal threaded portion 9a of the outer cylinder 9.
A pin 19 having a head fitted into a round hole or axially extending elongated slot formed in the inner periphery of the soft focus control ring 11 extends through an annular slot formed in the stationary cylinder 7 and threadingly fits into the threaded slot 9c formed in the outer cylinder 9. Accordingly, the control ring 11 and the outer cylinder 9 will rotate as one unit. A lever 16 extends parallel to the optical axis and engages the diaphragm associated pin to form a diaphragm control lever. The lever 16 is in turn connected to a ring 17 which is also connected to a pin 21 extending beyond the rear surface of the stationary cylinder 7. The pin 21 is designed to extend into the inside of the camera body thus forming an automatic diaphragm linkage that is adapted to rotate the diaphragm support ring 15 to any desired predetermined opening. As can be appreciated, the mounting of the lens mounting members for linear movement plus the provision of appropriate openings permits the operation of the diaphragm without any interference.
The following description is directed to the modes of operation of the mechanism of the present invention. To facilitate a better understanding of the invention, it is convenient to start with a mode of operation in which the distance adjusting ring 10 is rotated for the purposes of focusing relative to the initial condition disclosed in the illustration of FIG. 2. Accordingly, reference is made to both FIG. 2 and FIG. 3.
Since the second lens barrel 5 is prevented from rotation about the optical axis by the engagement of the linear slot 5c and the key 14, the distance adjusting ring 10 is displaced in the direction of the optical axis as it is rotated. This displacement is governed by the pitch of the second helicoid formed between threads 5b and 10b. The first lens barrel 4, however, is also precluded from rotation about the optical axis by the linear slot 5b in the key 13. Therefore, as a result of the coaction of the helicoid formed by the threads 4a and 10a, the first lens barrel 4 will be shifted forward and in the direction of the optical axis as a result of the rotation of the distance adjusting ring 10. Thus, with reference to the stationary cylinder 7, the first lens barrel 4 is shifted without being accompanied by any rotation. The movement or shift is according to the composite pitch of the first and second helicoids and will result in a displacement of the lens elements from the condition illustrated in FIG. 2 to the condition shown in FIG. 3. This shifting movement will adjust the air space between the first lens group 1 and the second lens group 2, thereby permitting optimum focusing from infinity to a relatively close distance. Since the rotation of the distance adjusting ring 10 has no influence whatsoever upon the second lens barrel 5 and the third lens barrel 6, these lens barrels will remain stationary.
Assuming that the proper focus has been reached and the photographer desires to introduce a soft focus condition, he will then rotate the soft focus control ring 11. For purposes of description, it will be assumed that FIG. 2 has provided the optimized focusing condition for normal photography. Reference is then made to FIG. 4 for comparison purposes. As the soft focus control ring 11 is rotated, it also rotates the translational or outer cylinder 9. The outer cylinder 9 translates this rotational force into a linear movement through the coaction of the cam like lead opening 9b formed in the outer cylinder 9 and the follower guide pin 18. This linear movement is achieved since the follower guide pin 18 is also journalled into the linear slot 7a formed in the stationary cylinder 7. Thus, the guide pin 18 will retract rearwardly and in parallel with the optical axis whereby the third lens barrel 6 will also be shifted rearwardly in the direction of the optical axis without any rotation. The second lens barrel 5 is precluded from any rotation as a result of the interface of the linear slot 5c in the key 14. Therefore, as a result of the action of the third helicoid 5a, 9a, the second lens barrel 5 will be shifted rearwardly along the optical axis. Since no relative movement takes place between the first helicoid elements 4a and 10a or between the second helicoid elements 5b and 10b, the distance adjusting ring and the first lens barrel 4 are shifted as a unit with the second barrel 5 rearwardly in the direction of the optical axis. As a result, the air space between the first lens group 1 and the second lens group 2 is held constant.
In the specific embodiments disclosed, the pitch of the lead opening 9b in the outer cylinder 9 is greater than the pitch of the third helicoid 5a, 9a and accordingly, the ratio of the rearward shift of the third lens barrel 6 is greater than that of the second lens barrel 5. The result is that the air space between the second lens group 2 and the third lens group 3 will be widened. It should be realized the pitch of the third helicoid 5a, 9a and the pitch or configuration of the lead opening 9b are also determined so that any compensation may be made for the deviation of the image plane from the focal plane due to a variation in the air space between the second lens group and the third lens group.
Thus, when the soft focus control ring 11 is rotated from the condition of FIG. 3, the third lens group 3 is shifted rearwardly by the action of the linear slot 7a and the cam like lead opening 9b. While the second lens group 2 is also shifted rearwardly by the action of the third helicoid 5a and 9a. Since there is no relative movement associated with the first helicoid 4a, 10a or the second helicoid 5b, 10b, the first lens group 1 is shifted as a unit with the second lens group 2 rearwardly with the air space between the first lens group 1 and second lens group 2, as shown in FIG. 3 being kept unchanged.
Accordingly, the first mode of operation for focusing and the second mode of operation for a soft focus control can be accomplished as described above. In both of the modes of operation the shifting of the respective lens groups are along the optical axis without any accompanying rotation. Therefore, any attachment mounts such as indicated at 4c may be suitably provided on the first lens barrel 4. Since the attachment mount 4c, thus provided, will not turn even when the first lens group 1 is shifted in the direction of the optical axis, it can accept any attachment wherein rotation would be objectionable such as a polarization filter or a rectangular hood. Moreover, since each lens group is shifted in the direction of the optical axis without any rotation, any eccentric dislocation between these lens groups can be avoided.
It also should be appreciated that since the lens groups do not rotate that this simplifies the diaphragm control. Thus, as explained in connection with FIG. 2, the diameter of the diaphragm aperture is controlled by the follower pin 20, and the openings in the mounting lens barrels permit this follower pin to be activated without any interference.
As can be readily appreciated, it is possible to deviate from the above embodiment of the present invention and as will be readily understood by those skilled in the art, the invention is capable of many modifications and improvements within the scope and spirit thereof. Accordingly, it will be understood that the invention is not to be limited by the specific disclosed embodiment but only by the scope and spirit of the appended claims.
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A compact optical lens barrel mechanism for relativenonrotational displacement of a series of lens elements forming an optical system is provided. Lens elements can be mounted for selective subdivision into operative lens groups for both focusing and introducing a variable soft focus condition. The barrel mechanism includes a mounting cylinder having appropriate linear alignment elements. A translational cylinder is rotatively journalled within the mounting cylinder. Three lens mounting members can be relatively movable and are designed to each carry a predetermined number of lens elements. The rear lens mounting member can be moved by the translational cylinder to provide a variable amount of spherical aberration to produce a soft focus condition. An exterior focusing ring and a soft focus condition ring can be rotatively mounted relative to the stationary mounting cylinder for linearly moving the respective mounting members.
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BACKGROUND OF THE INVENTION
This application covers our invention relating generally to double acting simplex plunger pumps. Our invention specifically is applicable as a modification and improvement of the pump invention described and claimed in the patent application of James E. Cook filed concurrently with this application Ser. No. 07/766,331, and filed Sep. 27, 1991. The aforesaid improvements may generally be described as an improved precision aligning means and an improved structural or holding means for aligning and holding together the individual component parts of the pump.
SUMMARY OF THE INVENTION
The present invention provides an improved double acting simplex plunger pump characterized by having unique alignment and structural means.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the assembled pump,
FIG. 2 is a view, partly in section, of the pump,
FIG. 3 is an end view, partly in section, of the apparatus shown in FIG. 2, with a portion of the manifold removed,
FIG. 4 is a transverse section of the manifold and one of the combined stuffing box and head members,
FIGS. 5 and 6 are bottom and end views respectively of the manifold,
FIGS. 7, 8 and 9 are views of one of the two identical combined stuffing box and head members, FIG. 7 being a view of the side adapted to be in engagement with the manifold, FIG. 8 being a view of the transverse side that includes the plunger receiving recess, and FIG. 9 being a view of the side adapted to the engagement with the motor face,
FIG. 10 is a view of the guide and seal retainer,
FIG. 11 is a view on an enlarged scale of one of the two identical check valves used in the pump,
FIG. 12 is an end view of the motor means, and
FIG. 13 is a side view of the motor means shown in FIG. 12 with only a portion of the motor depicted.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the reference numeral 10 is used to designate the entire improved pump. In broad terms the pump comprises a motor mean 20, a pair of combined stuffing box and head members 30A and 30B, a manifold member 50, and a plunger member 70 (see FIG. 2). FIG. 1 also shows three mutually orthogonal axes X, Y and Z. The X axis is aligned with and/or parallel to the output rotational axis of the motor 20. The Y and Z axes are, for example, representative of the longitudinal axis and one of the transverse axes of the manifold 50. The Y axis is also parallel to the longitudinal or reciprocational axis of the plunger member 70. Further the Y and Z axes define a plane which is parallel to several important surfaces of elements of the pump as will be described below.
The combined stuffing box and head members 30A and 30B are identical subassemblies having identical piece parts and are arranged, as assembled and as shown in FIGS. 1 and 2, in a reverse or opposite sense as is apparent from the drawings. Each of the combined stuffing box and head members 30A and 30B comprises a unitary block 31, shown most clearly in FIGS. 7-9, having two spaced apart and parallel surfaces 32 and 34, shown best in FIGS. 2 and 8. The flat surface 32 is also designated as a motor end plate engaging surface; the flat surface 34 is designated a pump manifold engaging surface. The unitary block 31, as shown most clearly in FIG. 8, has a constant width between the aforedescribed parallel surfaces 32 and 34. As clearly shown in FIGS. 1, 2 and 3 when the members 30A and 30B are is assembled position, then the parallel surfaces 32 and 34 are also parallel to the aforementioned Y-Z plane and the members 30A and 30B are spaced apart from one another along the longitudinal plunger axis. The other two sides of the block 31, i.e., transverse to sides 32 and 34, and as shown in FIGS. 7 and 9, are defined by the block having a relatively thick center portion bounded by two generally parallel surfaces 11 and 12. Surface 11 is relatively short and surface 12 extends substantially the entire length. A pair of sloping sides 13 extends from the ends of surface 11 in the direction of surface 12. The juncture of surfaces 12 and 13 is a rounded connection designated by reference numeral 14. A pair of large apertures 15 are provided and are shown in FIGS. 7 and 9.
The block 31 is preferably made from an extrusion of a suitable aluminum alloy such as 6061 aluminum with each block being a slice from the extrusion with the flat parallel surfaces 32 and 34 resulting from the slicing process. Thus a basic extrusion is obtained having the aforementioned external surfaces 11, 12, 13 and 14 as well as the large apertures 15. The "slicing" step will be understood by those skilled in the art to include, by way of example, sawing, milling, and grinding.
Each combined stuffing box and head member also includes a deep recess 35 in the block 31 formed by precision boring and extending inwardly from surface 12 (see FIGS. 7 and 8) for receiving one of the ends 70A and 70B of the cylindrically shaped and reciprocating plunger 70, as shown in FIG. 2. The recesses 35 have a circular cross section with a preselected diameter to snuggly receive but not contact the ends 70A and 70B of the plunger. When members 30A and 30B are in the aforesaid assembled position shown in FIGS. 1-3 the longitudinal axes of the recesses 35 of both blocks 31 are in alignment and thus have a common longitudinal axis lying parallel to the reference axis Y and between the spaced apart parallel surfaces 32 and 34. The diameter and the longitudinal length of the recess 35 are preselected to provide the desired pumping performance.
Each block 31 has an additional plunger guide and stuffing recess 37 concentric with the recess 35 and of a larger diameter for receiving a high pressure seal assembly 38 and a plunger guide or bearing 39. The seal 38 and plunger guide 39 are retained in the assembled relationship shown in FIG. 2 by a rectangularly shaped retainer 40 (see FIG. 10) having a centrally positioned opening 40' for accommodating but not contacting or restraining the reciprocating plunger. The retainer 40 is affixed to the block 31 by suitable attachment means such as machine screws 41 (shown in FIGS. 2 and 3) which pass through apertures 41' of retainer 40 and screw into threaded bores 41" of block 31 (see FIG. 8).
Each combined stuffing box and head member 30A and 30B further comprises a set of first and second pump port recesses 43 and 44 which start at the pump manifold engaging surface 34 and extend preferably perpendicularly into the block 31 a sufficient preselected distance so as to be in connective relationship with the plunger receiving recess 35, this being shown clearly in FIGS. 4 and 7. Recesses 43 and 44 are shown to have longitudinal axes which are parallel to each other and to the reference axis X. Recesses 43 and 44 further are located symmetrically on opposite sides of the longitudinal axis of recess 35. Additional slightly larger diameter recesses 43A and 44A are provided concentric respectively with recesses 43 and 44 adjacent to surface 34 and provide a seat and one half of a combined enclosure for check valve means to be described below. Also, countersunk or beveled surfaces 43A' and 44A' are provided (as shown in FIG. 8) adjacent to 43A and 44A respectively.
Each block 31 has on surface 32 thereof an arcuate shaped recess providing a flat surface 32' which is parallel to the primary surface 32 and with an arcuate surface 22B selected so as to be of the same radius as 22A of shoulder portion 22 of the motor, as shown in FIGS. 12 and 13.
The manifold 50 is a unitary member having a flat rectangular shape with a longitudinal axis A, shown in FIG. 5 and parallel to reference axis Y. The manifold member 50 has a central relatively thick portion 51 extending the full length and a pair of relatively thin flange portions 52 and 53 extending from opposite sides of portion 51 as best shown in FIG. 6. First and second spaced apart manifold inlet/outlet ports 55 and 56 extend longitudinally through the entire central portion 51 from a first end 51L to a second end 51R (see FIGS. 1 and 5). The manifold inlet/outlet ports 55 and 56 are mutually parallel to the manifold longitudinal axis (also reference axis Y) and the ends of the ports 55 and 56 adjacent to ends 51L and 51R are threaded or equivalent as at 55T and 56T to receive appropriate inlet and outlet piping. In practice, there typically would be one inlet and one outlet; in this case the two unused ports would be sealed off with standard plugs. Alternately there could be a double inlet and a double outlet. Additional inlets and outlets may be provided along and perpendicular to ports 55 and 56.
Importantly the manifold member 50 has a bottom flat surface 50B (FIG. 6) which is adapted to be abutted by said pump manifold engaging surfaces 34 of the combined stuffing box and head members 30A and 30B as is best shown in FIGS. 2 and 4. The manifold 50 is preferably made of the same material as block 31 and is formed by an extrusion process whereby the longitudinal ports 55 and 56 are integral with the extrusion, i.e., formed by the extrusion process.
Communicating with the longitudinally extending ports 55 and 56 in the manifold are two sets of transversely extending ports, the first set being adjacent end 51R and identified by reference numerals 60 and 61 (for coaction with pump port recesses 43 and 44 of combined stuffing box and head member 30B). The second set of transversely extending manifold ports are adjacent end 51L and is identified by reference numerals 62 and 63. Port set 62/63 is intended for coaction with the pump port recesses 43 and 44 of combined stuffing box and head member 30A. Port sets 60/61 and 62/63 are preferably provided by a boring or drilling operation and are longitudinally spaced apart a preselected distance so that when the manifold is in an assembled relationship as shown in FIGS. 1-4, each of said sets of ports 60/61 and 62/63 will be in alignment with and in register with a set of pump port recesses 43 and 44 in members 30A and 30B respectively.
The sets of manifold transverse ports 60/61, and 62/63 have associated additional and slightly larger recesses concentric therewith and are identified respectively by reference numerals 60A, 61A, 62A and 63A, these additional recesses are concentric with ports 60-63 respectively and are of a preselected diameter and of an axial depth (together with recesses 43A and 44A) to provide a combined enclosure (see FIG. 4) for check valve means identified by reference numerals 66 and 67. Check valve 66 is shown enlarged in FIG. 11. Check valves 66 and 67 as indicated are identical and are of standard form and function, i.e., they have a cylindrical shape with an outer circumferential surface 68 and of a short axial length. In FIG. 11 the directional arrow AA designates the direction of fluid flow through the check valve means upon a pressure differential being applied across the axial ends of the check valve, as is well understood by those skilled in the art. An O ring 69 is provided encompassing the outer circumferential surface 68.
As indicated, the check valves 66 and 67 are positioned between the manifold and members 30A and 30B in opposite senses as is clearly shown in FIG. 4. As shown, check valve 66 will admit fluid flow from manifold port 56 through check valve 66 and thence, via 44, into plunger recess 35 while check valve 67 permits fluid flow of the reverse sense, i.e., from plunger recess 35 through passageway 43, check valve 67 into manifold port 55.
As indicated above, the manifold recesses 60A, 61A, 62A and 63A in conjunction with the two sets of recesses 43A and 44A of members 30A and 30B provide a combined enclosure for the check valve means 66 and 67. Beveled surfaces 60A', 61A', 62A' and 63A' are provided adjacent recesses 60A-63A respectively and essentially are of the same diameter but of reverse slope of means 43A' and 44A'; Thus, the combined enclosure has a circumferential "V shaped" recess for receiving the O ring 69, as shown best in FIGS. 4 and 11.
The valves 66 and 67 as shown have three very important functions in addition to the valving function as described above; these functions are (i) providing a precision alignment means, (ii) providing a structural or holding means for assisting the holding of the entire assembly together, and (iii) providing an energy absorption all as described below in more detail.
The plunger 70 (see FIGS. 2 and 3) comprises a unitary cylindrical shaft having a preselected longitudinal length with first and second plunger means on the ends thereof; it will be understood that (as shown) the actual pumping function is provided by the snug but noncontacting fit of the plunger shaft into the coacting plunger receiving recess 35 of the combined stuffing box and head. Thus the ends of the plunger member, when the same is reciprocated, provide an alternating pumping action by displacing fluid in the receiving recess 35, i.e., first at one end, e.g., member 30A, and then at the other end, e.g., 30B; hence the designator "double acting". Other or piston configurations may be used with this invention, e.g., see the arrangements depicted in FIGS. 19 and 20 of the aforesaid prior U.S. Pat. No. 4,978,284.
The mid section of the shaft 70 is cut away as is shown in FIG. 2 providing two shoulder-like surfaces 71 and 72 which are adapted to be engaged by a crank eccentric or cam means 80 which is connected to the end of a rotatable shaft 81 of the motor means 20. Cam means 80 is shown in a "12 o'clock position in FIG. 3. The variation or extent of the eccentric directly varies the pump displacement.
As shown, motor means 20 is representative of electric motors (A.C. and D.C.) having an output rotatable shaft. However, the invention may be used with other motors such as hydraulic and pneumatic. The motor 20 has a planar axial end face or surface 21 with a central axially extending shoulder portion 22 having a circumferential surface 22A. The rotational axis of shaft 81 is perpendicular to the planar end face 21. The combined stuffing box and head members 30A and 30B are spaced apart as shown in FIGS. 1, 2 and 3 and preassembled with the plunger member 70 and such sub-assembly is then clamped between the planar axial end face 21 of the motor 20 and the manifold 50, as shown clearly in FIG. 2, by having the surfaces 32 in abutting engagement with surface 21 of the motor and by having surfaces 34 in abutting engagement with manifold planar surface 50B. During said assembly, the arcuate surfaces 22B coact with the circumferential surface 22A of the shoulder 22 of the motor 20. Thus, planar surfaces 32' of 30A and 30B will be abutting against portions of the planar axial end surface 21 and arcuate surfaces 22B of 30A and 30B will be abutting against portions of the circumferential surface 22A.
Means are provided to absorb the energy of the reciprocation of the plunger 70, i.e., (i) the clamping of members 30A and 30B (at arcuate surfaces 22B thereof) against the arcuate surface 22A of shoulder portion 22 of motor means 20, and (ii) the aforedescribed linkage of manifold 50, members 30A and 30B, check valves 66 and 67, and the motor means. Further the check valves 66 and 67, per se, act or function as energy absorbers.
As indicated, one category of motor means which may be used as an element of the invention is an electric motor of the type commercially available in numerous sizes and power ratings from several different suppliers; such motors usually have a shoulder means similar to shoulder 22 and the arcuate surface corresponding to 22A of such motors are usually held to close, low or small tolerances in order to meet customer requirements. This invention takes advantage of said low tolerance of surface 22A by using this surface as the reference for the pump design, regard being given to the clamping of arcuate surfaces 22B of members 30A and 30B against surface 22A all as aforesaid.
While the preferred embodiment of the invention using the contact or engagement of (i) surface 22A with surface 22B and (ii) surface 21 with surface 32, the scope of the invention includes, if desired, an engagement or contact of surface 22 of the motor means with surface 32' of members 30A and 30B in addition to or in place of the engagement of surfaces 21/32.
The members 30A and 30B are key to the unique construction of the invention of said copending application of James E. Cook. By having the members constructed from identical blocks 31 (and with surfaces 32 thereof abutting surface 21 of the motor means) with the axes of recesses 35 and the end surfaces 32 and 34 being mutually parallel, (and also parallel to the Y-Z plane) then a first very important criteria is satisfied, i.e., the longitudinal axes of the two recesses 35 are parallel to the planar surface 21 of the motor means 20.
The next key construction feature is that the members 30A and 30B are oriented with respect to each other so that the aforesaid longitudinal axes of the recesses 35 are in precise alignment; the resultant common axis thus defines the reciprocational or longitudinal axis for the plunger 70. The present invention provides an improved means for aligning the axes of recesses 35 as follows. The recesses 43/43A and 44/44A of the members 30A and 30B and the recesses 60/60A and 62/62A of the manifold are bored (or equivalent) using precision procedures. Upon the insertion of the check vlave means into the "combined enclosures" defined by the said recesses upon assembly of the pump the members 30A and 30B will be automatically oriented with respect to the reference "X" axis so that the aforesaid alignment is achieved. The outer circumferential surface 68 of the check valves is preselected so that the check valves snugly fit within the "combined enclosure" to assure the desired degree of alignment.
Thus the present invention provides an advantageous complement to the pump claimed in said copending application of James E. Cook wherein the unique members 30A and 30B with parallel surfaces 30 and 32 function, upon assembly, to automatically position the aforesaid longitudinal axes of said recesses 35 in a plane (parallel to the Y-Z reference plane) which is parallel to the end face 21 of the motor means. The present invention provides an effective and low cost means for having said longitudinal axis in alignment, a pre-requisite for receiving the plunger and long term operation of the pump.
The present invention also provides a means to hold members 30A and 30B from moving away from one another along the plunger axis as a reaction to the force of the reciprocating plunger moving into the recesses 35; said means, in broad terms, includes the manifold and, in general, a connection between the manifold, the members 30A and 30B and the motor means. The specific holding arrangement depicted is for a preferred embodiment of this invention and includes the manifold being connected to (i) members 30A and 30B as aforesaid, i.e., the two sets of check valves 66 and 67 residing in the combined enclosures, and (ii) the motor end face by four machine screws 90 having head means abutting the outboard surfaces of flanges 52 and 53 of the manifold and extending parallel to the reference axis X through apertures 15 of the combined stuffing box and head members 30A and 30B and into appropriate threaded recesses 90M in the axial end face 21 of the motor 20. Thus the check valves residing in the combined enclosure, as aforesaid, provide a strong structural linkage between the manifold and the members 30A and 30B; said linkage thus prevents any "outboard" travel of the members 30A and 30B, i.e., travel along the longitudinal axis of the plunger away from the motor axis.
In summary, the check valves, positioned as aforesaid, provide three important functions energy absorption and of facilitating the alignment and holding of the members 30A and 30B.
It is to be understood that the embodiment of our invention shown is only for the purpose of illustration and that our invention is limited solely by the scope of the appended claims.
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A double acting simplex plunger pump comprising a pair of unique unitary combined stuffing box and head members pre-assembled with a double ended plunger, the subassembly being sandwiched between the axial end face of a drive motor and a flat surface of a unitary manifold means and further characterized by means including check valve means for aligning and holding the members.
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FIELD OF THE INVENTION
A process in which the fuel properties of coal and crude petroleum are simultaneously improved is described. In this process, the coal and crude petroleum (and/or the residual product from the conventional refining of crude petroleum) are contacted with each other while being subjected to a temperature of from about 850 to about 1,000 degrees Fahrenheit in a fluidized bed.
BACKGROUND OF THE INVENTION
The most abundant coal resource in western North America and Canada is the low rank coals, which include sub-bituminous coal and lignite. Many deposits of these coals are relatively easy to mine; but, unfortunately, they contain large amounts of moisture. High levels of moisture result in low calorific values for the coal. Coal with high levels of moisture not only costs more to transport, but substantially more if it must be combusted for a given heat output.
The higher-rank coals, many of which are found in the Eastern United States, suffer from another disadvantage--they often contain substantial amounts of ash. The ash, in addition to lowering the calorific value of the coal, will cause erosion of boilers when the coal is burned and pollution of the environment. Environmental regulations necessitate the use of expensive ash-recovery facilities.
A similar problem exists with crude oil, particularly heavy crude oils. There are substantial reserves of heavy crude oil in Western Canada and Venezuela; the reserves of heavy crude oil in Venezuela are believed to be at least equal to the known recoverable reserves of conventional crude oils in the rest of the world. This oil generally has an American Petroleum Institute ("A.P.I.") gravity of less than about 10. Petroleum refiners prefer to work with crude oils with an A.P.I. of at least about 20, for such oil is substantially more economical to process to much higher value products.
Processes for reducing the moisture content of coals are well known to those skilled in the art.
Thus, for example, in 1923, in U.S. Pat. No. 1,477,642, Benjamin Gallsworthy disclosed that certain low grade crude petroleums contained a substantial amount of moisture. Gallsworthy taught a process in which the oil was sprayed over heated lignite and allowed to percolate through the lignite. The lignite used in Gallsworthy's process had to be substantially moisture-free prior to the time it was contacted with the oil.
In 1926, in U.S. Pat. No. 1,574,174, Eugene Shoch disclosed a process in which fresh lump lignite is heated in a still while immersed in thin petroleum oil. Shoch taught that, in general, such lignite should not be heated to a temperature in excess of 300 degrees Centigrade, stating that (at page 1) "Fresh lignite . . . frequently contains . . . from 25% to 35% of moisture, which it loses when heated at 110 degrees C. . . . Heated above this temperature, to 300 degrees C., it gives up still more moisture, and some carbon dioxide; and heated still higher it begins to yield tar, and some combustible gases; the deepseated decomposition which it then undergoes involves an exothermic reaction so that the heating power of the products when used as a fuel is less than that of the original material . . . ."
In 1932, in U.S. Pat. No. 1,871,862, Eugene Shoch again disclosed that, when lignite is heated to a temperature in excess of 300 degrees Centigrade, it undergoes an exothermic reaction.
In 1939, yet another lignite dehydration patent was issued to Eugene Shoch. In U.S. Pat. No. 2,183,924, Shoch disclosed that lignite is subject to disintegration when it is dehydrated, stating that (at page 1) " . . . when lignite is heated in dryers or retorts to remove this moisture, it also undergoes such extensive disintegration." In the process of this patent, Shoch submerged the lignite under a hydrocarbon oil while maintaining both within a closed vessel, and he heated the contents of the closed vessel to a maximum temperature of from 200 to 220 degrees Centigrade.
In 1952, in U.S. Pat. No. 2,610,115, Henry Lykken disclosed a method for dehydrating lignite. In the first step of this process, the lignite was crushed and then screened to a size not substantially exceeding 1 inch mesh. Thereafter, the screened lignite was mixed with from 3 to 10 percent of a mineral hydrocarbon oil. Thereafter, the lignite/oil mixture was heated to a maximum temperature of 300 degrees Fahrenheit.
In 1957 Lykken was issued another lignite dehydration patent. In U.S. Pat. No. 2,811,427 he again disclosed a process in which a lignite/oil mixture was heated to a maximum temperature of 300 degrees Fahrenheit.
A third lignite dehydration patent (U.S. Pat. No. 2,966,400) was issued to Lykken in 1960. In the process of this patent, coarsely crushed and screened lignite was fed with a minor amount (3-10 weight percent) of fluidal hydrocarbon material into and through a rotary preheating kiln, and then into and through a rotary processing kiln in which the temperature of the lignite is raised to about 600 degrees Fahrenheit.
In 1972 U.S. Pat. No. 3,754,876 was issued to Robert E. Pennington et al. The patentees disclosed a process for removing water from sub-bituminous or lower rank coal in which the coal is contacted with a "stream of inert hydrogenpoor hydrocarbonaceous heat transfer fluid . . . ." At column 3, the patentees taught that the fluid used in their process must have a hydrogen-to-carbon ratio of less than 1.5. They also teach that petroleum oils, which generally have higher hydrogen-to-carbon rations (1.5 to 2.0), should not be used in the process of their invention.
In 1976, in U.S. Pat. Nos. 3,985,516 and 3,985,517, Clarence Johnson disclosed a process in which particulate pyrophoric low rank coal was contacted with from 0.5 to 5 percent of hydrocarbon liquid while in a fluidized bed and while being heated to a temperature of from 250 to 500 degrees Fahrenheit.
In 1980, in U.S. Pat. No. 4,213,752, Walter Seitzer disclosed a lignite dehydration process in which the coal was passed into a moving bed of hot coal at a temperature in the range of from about 200 to about 300 degrees Centigrade.
In 1982, in U.S. Pat. No. 4,309,192, Isao Kubo et al. disclosed a process for the treatment of "water-containing coal." In the first step of this process, a mixture of such coal and a hydrocarbon oil is provided. Thereafter, such mixture is heated at a temperature of from 100 to 350 degrees Centigrade.
In 1984, in U.S Pat. No. 4,461,624, Brian Wong disclosed a process for improving the calorific value of lowrank coal. In the first step of this process, the coal was crushed to a particle size of 0.1 to 3 centimeters. Thereafter, the crushed coal was immersed in a distillation residuum of petroleum crude oil at a temperature of from 240 to 350 degrees Centigrade.
In 1985, in U.S. Pat. No. 4,504,274, Ardis Anderson disclosed that dried coal has a " . . . tendency toward spontaneous combustion . . . " which presents " . . . a serious problem during the shipment and storage of such coal . . . ." In the process of this patent, a "coal spray" is used to coat the dried coal.
In 1985, in U.S. Pat. No. 4,547,198, James Skinner also disclosed that " . . . the dried coal produced by such processes frequently had a tendency to undergo spontaneous ignition and combustion in storage and transit . . . ." In order to minimize this pyrophoricity, Skinner passed the coal through a mist of oil.
In 1986, in U.S. Pat. No. 4,571,174, Walter Shelton disclosed that, in a fluidized bed, dried low rank coal has a tendency to ignite. At column 1 of hs patent, Shelton taught that: "The coal leaving a drying process for the removal of inherent water will typically be at a temperature of from bout 130 to about 250 degrees Fahrenheit. . . . When such processes for the removal of inherent water are applied to low rank coals, the coal has a tendency to ignite in the fluidized bed as a result of the contact between the high temperature gases normally used as a hot fluidizing gas to dry the coal and coal particles which have been dried to a relatively low water content."
It is an object of this invention to provide a process which enables one to simultaneously improve the fuel properties of coal and oil.
It is yet another object of this invention to provide a process for reducing the amount of moisture in coal.
It is yet another object of this invention to provide a dried coal which is substantially non pyrophoric.
It is yet another object of this invention to provide a dried coal with a substantially higher heating value than the parent coal from which it is derived.
It is yet another object of this invention to provide a dried coal which is substantially non deliquescent.
It is yet another object of this invention to provide a process for reducing the amount of sulfur in oil.
It is yet another object of this invention to provide an oil which has a substantially higher A.P.I. gravity than the parent oil from which it is derived.
SUMMARY OF THE INVENTION
In accordance with this invention, there is provided a process for simultaneously improving the fuel properties of coal and oil. In the first step of this process, a first fluidized bed (the reactor vessel) which has a density of from about 20 to about 50 pounds per cubic foot and which is at a temperature of from about 850 to about 1,000 degrees Fahrenheit is provided. In the second step of the process, coal and oil are continuously fed into the reactor vessel while fluidized particles are continuously removed from such vessel. In the third step of the process, the fluidized particles which are removed from the reactor vessel are transferred to a second fluidized bed (the burner vessel); at least a portion of these particles are combusted in the presence of air. In the fourth step of the process, at least a portion of the combusted fluidized particles are returned to the reactor vessel.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be more fully understood by reference to the following detailed description thereof, when read in conjunction with the attached drawing, wherein like reference numerals refer to like elements, and wherein:
FIG. 1 is a flow diagram illustrating a preferred embodiment of the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates one preferred embodiment of the process of this invention.
Referring to FIG. 1, a fluidized bed 10 is provided in a reactor vessel 12. This fluidized bed 10 is comprised of hot coal, and it preferably has a density of from about 20 to about 50 pounds per cubic foot. It is preferred that the fluidizing gas be passed through the bed at a velocity of from about 1 to about 5 feet per second.
Fluidized bed 10 may be provided by any of the means well known to those skilled in the art. Thus, for example, one may use the means described in J. M. Coulson et al.'s "Chemical Engineering," Volume Two, Third Edition (Pergamon Press, Oxford, England, 1978, pages 230-280), the disclosure of which is hereby incorporated by reference into this specification; reference may be had, e.g., to pages 272-274 of said book which describes the fluidized bed combustion of coal.
By way of specific illustration and not limitation, fluidized bed 10 may be provided by a process in which sand is first charged into reactor vessel 12 via riser 14; this process also provides a fluidized bed 11 in burner vessel 24. Thereafter, heated air at a temperature of about 1,000 degrees Fahrenheit is injected via line 16 at a fluidizing velocity in the reactor vessel of from about 1 to about 3 feet per second; the air is injected until the temperature of the fluidized sand is about 1,000 degrees Fahrenheit. Thereafter, the air flow is ceased, and oil is added via line 18, thereby forming a fluidized mixture; a portion of this fluidized mixture is then withdrawn through standpipe 20 and passed through riser 22 to burner vessel 24. A portion of the carbonized material in the fluidized mixture in burner vessel 24 is then treated with air injected through line 26 and heated to a temperature which is from about 25 to about 100 degrees hotter than the temperature in reactor vessel 12. A portion of the fluidized material in burner vessel 24 is continually withdrawn through standpipe 28 and passed through riser 30 to reactor vessel 12. A portion of the material in burner vessel 24 is withdrawn through line 32 and discarded to reduce the amount of sand in the system. At about the same time, coal is introduced into reactor vessel 12 via line 14. This process is continued until the beds in reactor vessel 12 and burner vessel 24 consist essentially of carbonaceous material.
Via this startup process, or any other conventional process for providing a fluidized bed, fluidized beds 10 and 11 are provided.
Each of fluidized beds 10 and 11 preferably has a fluidized density of from about 20 to about 50 pounds per cubic foot. As will be apparent to those skilled in the art, the fluidized density is the density of the bed while its materials are in the fluid state and does not refer to the particulate density of the materials in the bed.
Each of fluidized beds 10 and 11 is comprised of at least about 80 weight percent of carbonaceous material. The carbonaceous material may be coal, coke, and mixtures thereof. Non-carbonaceous materials, such as sulfur and ash, also may be present in the bed(s) in minor amounts.
Fluidized beds 10 and 11 are maintained at a temperature of from about 850 to about 1,050 degrees Fahrenheit. Fluidized bed 10 is maintained at a temperature of from about 850 to about 1,000 degrees Fahrenheit, and fluidized bed 11 is maintained at a temperature of from about 850 to about 1,050 degrees Fahrenheit, provided that the temperature of fluidized bed 11 is least about 25 degrees higher than that used in bed 10.
After fluidized bed 10 has been established in a steadystate condition, coal is fed into fluidized bed 10 via line 14, and oil is fed into fluidized bed 10 via line 18. The coal and oil are fed into bed 10 at rates such the feed rate of the coal (in pounds per hour) is from about 0.05 to about 20 times as great as the feed rate of the oil. In one embodiment, the feed rate of the coal is from about 0.1 to about 10 times as great as the feed rate of the oil.
In one embodiment, wherein the primary goal of the process is to upgrade coal, from about 50 to about 90 weight percent of coal (by total weight of coal and oil fed) is fed into the system. In another embodiment, where the primary goal of the system is to upgrade oil, from about 50 to 95 weight percent of oil is fed into the system.
The coal may be fed from any suitable container and by any suitable means. Thus, by way of illustration and referring again to FIG. 1, coal may be stored in hopper 13 and fed via line 14 to reactor vessel 12. Alternatively, coal may be fed via a screw conveyor (not shown), a star feeder (not shown), or any other suitable solid transport device.
In one embodiment, steam is added via line 34 to reactor vessel 12 in order to maintain fluidization of bed 10.
The coal which is added via line 14 may be any of the coals known to those skilled in the art. Thus, by way of illustration, one may treat lignite, subbituminous, bituminous, semibituminous, semianthracite, and anthracite coals. These coals are defined on page 222 of "A dictionary of mining, mineral, and related terms," complied and edited by Paul W. Thrush and the Staff of the Bureau of Mines (Washington, D.C., United States Bureau of Mines, Department of the Interior, 1968), the disclosure of which is hereby incorporated by reference into this specification. Reference also may be had to the International Committee for Coal Petrology's "International Handbook of Coal Petrology" (Centre National de la Recherche Scientifique, Paris, France, 2nd edition, 1963, parts I and II) and to pages 9-3 to 9-5 of Robert H. Perry et al.'s "Chemical Engineers' Handbook," Fifth Edition (McGraw-Hill Book Company, New York, 1973), the disclosure each of of which also is incorporated by reference into this specification.
In one preferred embodiment, the coal used in the process of the invention has a moisture content of at least about 10 weight percent, an ash content of at least about 10 weight percent, and a calorific value of less than about 9,000 British Thermal Units; this coal is described in U.S. Pat. No. 4,052,168, the description of which is hereby incorporated by reference into this specification. This preferred coal is often referred to as subbituminous coal. It is to be understood that these lower-rank coals exhibit the greatest improvement with the process of this invention. However, it will also be apparent to those skilled in the art that higher-rank coals also may be substantially improved with such process.
Any of the mineral oils known to those skilled in the art may be used in the process of this invention. As is known to those skilled in the art, mineral oils are derived from petroleum, coal, shale, and the like and consist essentially of hydrocarbons (see, e.g., page 764 of said "A dictionary of mining, mineral, and related terms," supra.
By way of illustration, liquid petroleum fuels may be used in the process of this invention. These liquid petroleum fuels are described on pages 9-8 through 9-11 of siad "Chemical Engineers' Handbook," supra, the disclosure of which is hereby incorporated by reference into this specification.
It is preferred that the oil used in the process of this invention have an A.P.I. gravity of from about 0 to about 15 As is known to those skilled in the art, A.P.I. gravity is determined at ambient temperature with specialized hydrometers, corrected to 60 degrees Fahrenheit, and expressed in degrees A.P.I., a scale that is related inversely to the specific gravity "s" at 60 degrees/60 degrees F., in accordance with the formula: degrees A.P.I.=141.5/s-131.5
By way of illustration and not limitation, one may use low gravity crude oils produced in Boscan, Venezuela (which typically have a gravity of 9.5 and contain about 5.2 weight percent of sulfur), in Lagunillas, Venezuela (which typically have a gravity of 10.6 and contain about 2.9 weight percent of sulfur), in Coleville, Canada (which typically have a gravity of 13.5 and contain about 3.2 percent of sulfur), and the like.
In the preferred embodiment illustrated in FIG. 1, reactor vessel 12 is equipped with exit line 36 which conveys reactor products and entrained solids to cyclone 38. Cyclone 38 separates the stream into gaseous hydrocarbon products and water vapor, which are then passed through line 40 to suitable recovery facilities (not shown). The entrained solids separated in cyclone 38 are returned to the fluid bed 10 via standpipe 42.
In one preferred embodiment, not shown, the standpipes and risers are equipped with suitable aeration taps (not shown) to maintain the fluidity of the circulating solids passing through them.
In one embodiment (not shown), instead of introducing the oil via line 18 and the coal via line 14, one or both of these components may be introduced into the lower section of riser 30 at point 44. As will be known to those skilled in the art, different coals and oils have different chemical reactivity rates and, thus, require, different residence times in the system. For those coals and/or oils which are less reactive, it might be advantageous to introduce them into the lower section of riser 30 at point 44 rather than introducing them directly into reactor vessel 12.
It is preferred that, at steady state, the pressure within reactor vessel 12 and within burner vessel 24 be no greater than about 15 p.s.ig.
The reaction occurring in reactor vessel 12 is endothermic. Accordingly, the heat of reaction is preferably supplied by burning a portion of the carbonaceous mixture from reaction vessel 12. A sufficient amount of such material is withdrawn from vessel 12 through standpipe 20 and riser 22 and thereafter burned in burner vessel 24. Inasmuch as the reaction temperature in vessel 24 is from about 25 to about 100 degrees higher than the temperature in vessel 12, combusted material passed from vessel 24 to vessel 12 will provide the heat of reaction required in vessel 12. Those skilled in the art can readily determine temperatures and flow rates needed to achieve a temperature balance within the system.
Carbonaceous material from burner 24 is continuously removed via line 32 in order to maintain a constant unit inventory. Those skilled in the art are well aware of how to balance the flow and discharge rates in order to obtain such inventory.
Burner vessel 24 is comprised of an exit line 46 and a cyclone 48. Exit line 46 carries combustion gases and entrained solids from fluid bed 11 to cyclone 48. Combustion gases exit through line 50, to vent; and entrained solids from cyclone 48 are returned to fluid bed 11 through standpipe 52.
As will be apparent to those skilled in the art, all streams which are significantly above ambient temperature may be connected to suitable heat recovery devices.
In one embodiment of this invention, the the coal used in the process of this invention is pretreated prior to being fed into reactor vessel 12. The coal so pretreated generally contains from about 0.5 to about 3.0 weight percent of oil, from about 10 to about 30 weight percent of moisture, and from about 5 to about 15 weight percent of ash.
A coal which contains from about 0.5 to about 3.0 weight percent of oil, from about 10 to about 30 weight percent of moisture, and from about 5 to about 15 weight percent of ash may be prepared by means well known to those skilled in the art.
By way of illustration, one may prepare such a coal by the process described in U.S. Pat. No. 4,854,940 of Jerzy S. Janiak, et al., the disclosure of which is hereby incorporated by reference into this specification. In the process of this patent, subbituminous coal is agglomerated with a "bridging liquid" consisting essentially of from about 20 to about 50 percent of a light hydrocarbon diluent (e.g., oils such as naptha, kerosene, diesel oil, and the like) and from about 50 to about 80 percent of a low quality heavy oil (e.g., bitumen, heavy crude, and other oils recognized in the art as being heavy oils).
By way of further illustration, the processes of the Lykken patents described elsewhere in this specification may be used to prepare a coal containing from about 3.0 weight percent of oil, from about 10 to about 30 weight percent of moisture, and from about 5 to about 15 weight percent of ash. Thus, for example, one may use the process described in U.S. Pat. No. 2,996,400, the disclosure of which is hereby incorporated by reference into this specification.
By way of further illustration, the processes described in U.S. Pat. Nos. 3,985,516 and/or 3,985,517 may be used in applicant's process.
In one embodiment, the coal which contains from about 0.5 to about 3.0 weight percent of oil, from about 10 to about 30 weight percent of moisture, and from about 5 to about 15 weight percent of ash is preheated to a temperature of from about 250 to about 350 degrees Fahrenehit prior to being introduced into reactor vessel 12.
Thus, by way of illustration and not limitation, and referring to FIG. 1, such coal may be introduced into container 13 by a suitable line. Hot gas (such as, e.g., the exhaust gas from line 50) may be introduced by a line (not shown) into container 13; it is preferred that the velocity of such hot gas be less than about 1.0 foot per second inasmuch as fluidization of the contents of such container need not be vigorous. The off gas from container 13 may be passed to cyclone 38 via a line (not shown). Any entrained solids may be returned to vessel 13 by a standpipe (not shown). Gases containing principally nitrogen, carbon dioxide, water vapor, and hydrocarbons may be transferred to a suitable recovery facility.
The coal in vessel 13, which contained from about 0.5 to about 3.0 weight percent of oil, from about 10 to about 30 weight percent of moisture, and from about 5 to about 15 weight percent of ash prior to the time it was heated to a temperature of from about 250 to about 350 degrees Fahrenheit, may then be fed into reactor vessel 12 and processed in the manner described for other coals elsewhere in this specification.
It is to be understood that the aforementioned description is illustrative only and that changes can be made in the apparatus, the ingredients and their proportions, and in the sequence of combinations and process steps as well as in other aspects of the invention discussed herein without departing from the scope of the invention as defined in the following claims.
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A process for simultaneously improving the fuel properties of coal and oil is described.
In the first step of this process, two fluidized beds are provided. The first fluidized bed has a fluidized density of from about 20 to about 50 pounds per cubic foot and is at a temperature of from about 850 to about 1,000 degrees Fahrenheit. The second fluidized bed is similar to the first but is at a slightly higher temperature.
Coal and oil are fed into the first fluidized bed. A portion of the coal/oil mixture from the first bed is fed to the second bed, wherein it is combusted. Combustion product from the second bed is fed to the first bed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/130,005 filed May 30, 2008, which is a continuation-in-part of U.S. patent application Ser. No. 11/497,566 filed Aug. 11, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/396,338 filed Mar. 31, 2006 which is a continuation-in-part of U.S. patent application Ser. Nos. 11/175,979 filed Jul. 6, 2005, and 11/384,012 filed Mar. 17, 2006, all of which are incorporated herein by reference in their entirety. U.S. patent application Ser. No. 11/175,979 claims the benefit of priority to U.S. Provisional Patent Application No. 60/585,804 filed Jul. 6, 2004, which is incorporated herein by reference in its entirety. U.S. patent application Ser. No. 11/384,012 claims the benefit of priority to U.S. Provisional Patent Application No. 60/663,491 filed Mar. 18, 2005, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to compositions and methods for using the mixed calcium/sodium salt of inositol-tripyrophosphate (ITPP-Ca/Na) to enhance oxygen delivery by red blood cells. ITPP-Ca/Na is an allosteric effector of hemoglobin which has the ability to cross the plasma membrane of red blood cells and lower the oxygen affinity of the hemoglobin of red blood cells. The present invention is further directed to the use of ITPP-Ca/Na to inhibit angiogenesis and enhance radiation sensitivity of hypoxic tumors. The present invention is further directed to the use of ITPP-Ca/Na to enhance the partial pressure of oxygen (PO 2 ) in hypoxic tumors.
BACKGROUND OF THE INVENTION
[0003] In the vascular system of an adult human being, blood has a volume of about 5 to 6 liters. Approximately one half of this volume is occupied by cells, including red blood cells (erythrocytes), white blood cells (leukocytes), and blood platelets. Red blood cells comprise the majority of the cellular components of blood. Plasma, the liquid portion of blood, is approximately 90 percent water and 10 percent various solutes. These solutes include plasma proteins, organic metabolites and waste products, and inorganic compounds.
[0004] The major function of red blood cells is to transport oxygen from the lungs to the tissues of the body, and transport carbon dioxide from the tissues to the lungs for removal. Very little oxygen is transported by the blood plasma because oxygen is only sparingly soluble in aqueous solutions. Most of the oxygen carried by the blood is transported by the hemoglobin of the erythrocytes. Erythrocytes in mammals do not contain nuclei, mitochondria or any other intracellular organelles, and they do not use oxygen in their own metabolism. Red blood cells contain about 35 percent by weight hemoglobin, which is responsible for binding and transporting oxygen.
[0005] Hemoglobin is a protein having a molecular weight of approximately 64,500 daltons. It contains four polypeptide chains and four heme prosthetic groups in which iron atoms are bound in the ferrous state. Normal globin, the protein portion of the hemoglobin molecule, consists of two alpha chains and two beta chains. Each of the four chains has a characteristic tertiary structure in which the chain is folded. The four polypeptide chains fit together in an approximately tetrahedral arrangement, to constitute the characteristic quaternary structure of hemoglobin. There is one heme group bound to each polypeptide chain which can reversibly bind one molecule of molecular oxygen. When hemoglobin combines with oxygen, oxyhemoglobin is formed. When oxygen is released, the oxyhemoglobin is reduced to deoxyhemoglobin.
[0006] Delivery of oxygen to tissues, including tumors, depends upon a number of factors including, but not limited to, the volume of blood flow, the number of red blood cells, the concentration of hemoglobin in the red blood cells, the oxygen affinity of the hemoglobin and, in certain species, on the molar ratio of intraerythrocytic hemoglobins with high and low oxygen affinity. The oxygen affinity of hemoglobin depends on four factors as well, namely: (1) the partial pressure of oxygen; (2) the pH; (3) the concentration of 2,3-diphosphoglycerate (DPG) in the hemoglobin; and (4) the concentration of carbon dioxide. In the lungs, at an oxygen partial pressure of 100 mm Hg, approximately 98% of circulating hemoglobin is saturated with oxygen. This represents the total oxygen transport capacity of the blood. When fully oxygenated, 100 ml of whole mammalian blood can carry about 21 ml of gaseous oxygen.
[0007] The effect of the partial pressure of oxygen and the pH on the ability of hemoglobin to bind oxygen is best illustrated by examination of the oxygen saturation curve of hemoglobin. An oxygen saturation curve plots the percentage of total oxygen-binding sites of a hemoglobin molecule that are occupied by oxygen molecules when solutions of the hemoglobin molecule are in equilibrium with different partial pressures of oxygen in the gas phase.
[0008] The oxygen saturation curve for hemoglobin is sigmoid. Thus, binding the first molecule of oxygen increases the affinity of the remaining hemoglobin for binding additional oxygen molecules. As the partial pressure of oxygen is increased, a plateau is approached at which each of the hemoglobin molecules is saturated and contains the upper limit of four molecules of oxygen.
[0009] The reversible binding of oxygen by hemoglobin is accompanied by the release of protons, according to the equation:
[0000] HHb + +O 2 ⇄HbO 2 +H +
[0010] Thus, an increase in the pH will pull the equilibrium to the right and cause hemoglobin to bind more oxygen at a given partial pressure. A decrease in the pH will decrease the amount of oxygen bound.
[0011] In the lungs, the partial pressure of oxygen in the air spaces is approximately 90 to 100 mm Hg and the pH is also high relative to normal blood pH (up to 7.6). Therefore, hemoglobin will tend to become almost maximally saturated with oxygen in the lungs. At that pressure and pH, hemoglobin is approximately 98 percent saturated with oxygen. On the other hand, in the capillaries in the interior of the peripheral tissues, the partial pressure of oxygen is only about 25 to 40 mm Hg and the pH is also nearly neutral (about 7.2 to 7.3). Because muscle cells use oxygen at a high rate, thereby lowering the local concentration of oxygen, the release of some of the bound oxygen to the tissue is favored. As the blood passes through the capillaries in the muscles, oxygen will be released from the nearly saturated hemoglobin in the red blood cells into the blood plasma and then into the muscle cells. Hemoglobin will release about a fourth of its bound oxygen as it passes through the muscle capillaries, so that when it leaves the muscle, it will be only about 75 percent saturated. In general, the hemoglobin in the venous blood leaving the tissue cycles between about 65 and 97 percent saturation with oxygen in its repeated circuits between the lungs and the peripheral tissues. Thus, oxygen partial pressure and pH function together to effect the release of oxygen by hemoglobin.
[0012] A third important factor in regulating the degree of oxygenation of hemoglobin is the allosteric effector 2,3-diphosphoglycerate (DPG). DPG is the normal physiological effector of hemoglobin in mammalian erythrocytes. DPG regulates the oxygen-binding affinity of hemoglobin in the red blood cells in relationship to the oxygen partial pressure in the lungs. The higher the concentration of DPG in the cell, the lower the affinity of hemoglobin for oxygen.
[0013] When the delivery of oxygen to the tissues is chronically reduced, the concentration of DPG in the erythrocytes is higher than in normal individuals. For example, at high altitudes the partial pressure of oxygen is significantly less. Correspondingly, the partial pressure of oxygen in the tissues is less. Within a few hours after a normal human subject moves to a higher altitude, the DPG level in the red blood cells increases, causing more DPG to be bound and the oxygen affinity of the hemoglobin to decrease. Increases in the DPG level of red cells also occur in patients suffering from hypoxia. This adjustment allows the hemoglobin to release its bound oxygen more readily to the tissues to compensate for the decreased oxygenation of hemoglobin in the lungs. The reverse change occurs when people are acclimated to high altitudes and descend to lower altitudes.
[0014] As normally isolated from blood, hemoglobin contains a considerable amount of DPG. When hemoglobin is “stripped” of its DPG, it shows a much higher affinity for oxygen. When DPG is increased, the oxygen binding affinity of hemoglobin decreases. A physiologic allosteric effector such as DPG is therefore essential for the normal release of oxygen from hemoglobin in the tissues.
[0015] While DPG is the normal physiologic effector of hemoglobin in mammalian red blood cells, phosphorylated inositols are found to play the same role in the erythrocytes of some birds and reptiles. Although inositol hexaphosphate (IHP) is unable to pass through the mammalian erythrocyte membrane, it is capable of combining with hemoglobin of mammalian red blood cells at the binding site of DPG to modify the allosteric conformation of hemoglobin, the effect of which is to reduce the affinity of hemoglobin for oxygen. For example, DPG can be replaced by IHP, which is far more potent than DPG in reducing the oxygen affinity of hemoglobin. IHP has a 1000-fold higher affinity to hemoglobin than DPG (R. E. Benesch et al., Biochemistry, Vol. 16, pages 2594-2597 (1977)) and increases the P 50 of hemoglobin up to values of 96.4 mm, Hg at pH 7.4, and 37 degrees C. (J. Biol. Chem., Vol. 250, pages 7093-7098 (1975)).
[0016] The oxygen release capacity of mammalian red blood cells can be enhanced by introducing certain allosteric effectors of hemoglobin into erythrocytes, thereby decreasing the affinity of hemoglobin for oxygen and improving the oxygen economy of the blood. This phenomenon suggests various medical applications for treating individuals who are experiencing lowered oxygenation of their tissues due to the inadequate function of their lungs or circulatory system.
[0017] Because of the potential medical benefits to be achieved from the use of these modified erythrocytes, various techniques have been developed in the prior art to enable the encapsulation of allosteric effectors of hemoglobin in erythrocytes. Accordingly, numerous devices have been designed to assist or simplify the encapsulation procedure. The encapsulation methods known in the art include osmotic pulse (swelling) and reconstitution of cells, controlled lysis and resealing, incorporation of liposomes, and electroporation. Current methods of electroporation make the procedure commercially impractical on a scale suitable for commercial use.
[0018] The following references describe the incorporation of polyphosphates into red blood cells by the interaction of liposomes loaded with IHP: Gersonde, et al., “Modification of the Oxygen Affinity of Intracellular Hemoglobin by Incorporation of Polyphosphates into Intact Red Blood Cells and Enhanced O 2 Release in the Capillary System”, Biblthca. Haemat., No. 46, pp. 81-92 (1980); Gersonde, et al., “Enhancement of the O 2 Release Capacity and of the Bohr-Effect of Human Red Blood Cells after Incorporation of Inositol Hexaphosphate by Fusion with Effector-Containing Lipid Vesicles”, Origins of Cooperative Binding of Hemoglobin (1982); and Weiner, “Right Shifting of Hb—O 2 Dissociation in Viable Red Cells by Liposomal Technique,” Biology of the Cell, Vol. 47, (1983).
[0019] Additionally, U.S. Pat. Nos. 4,192,869, 4,321,259, and 4,473,563 to Nicolau et al. describe a method whereby fluid-charged lipid vesicles are fused with erythrocyte membranes, depositing their contents into the red blood cells. In this manner, it is possible to transport allosteric effectors, such as IHP into erythrocytes, where due to its much higher binding constant IHP replaces DPG at its binding site in hemoglobin.
[0020] In accordance with the liposome technique, IHP is dissolved in a phosphate buffer until the solution is saturated and a mixture of lipid vesicles is suspended in the solution. The suspension is then subjected to ultrasonic treatment or an injection process, and then centrifuged. The upper suspension contains small lipid vesicles containing IHP, which are then collected. Erythrocytes are added to the collected suspension and incubated, during which time the lipid vesicles containing IHP fuse with the cell membranes of the erythrocytes, thereby depositing their contents into the interior of the erythrocyte. The modified erythrocytes are then washed and added to plasma to complete the product.
[0021] The drawbacks associated with the liposomal technique include poor reproducibility of the IHP concentrations incorporated in the red blood cells and significant hemolysis of the red blood cells following treatment. Additionally, commercialization is not practical because the procedure is tedious and complicated.
[0022] In an attempt to solve the drawbacks associated with the liposomal technique, a method of lysing and the resealing red blood cells was developed. This method is described in the following publication: Nicolau, et al., “Incorporation of Allosteric Effectors of Hemoglobin in Red Blood Cells. Physiologic Effects,” Biblthca. Haemat., No. 51, pp. 92-107, (1985). Related U.S. Pat. Nos. 4,752,586 and 4,652,449 to Ropars et al. also describe a procedure of encapsulating substances having biological activity in human or animal erythrocytes by controlled lysis and resealing of the erythrocytes, which avoids the red blood cell-liposome interactions.
[0023] The technique is best characterized as a continuous flow dialysis system, which functions in a manner similar to the osmotic pulse technique. Specifically, the primary compartment of at least one dialysis element is continuously supplied with an aqueous suspension of erythrocytes, while the secondary compartment of the dialysis element contains an aqueous solution which is hypotonic with respect to the erythrocyte suspension. The hypotonic solution causes the erythrocytes to lyse. The erythrocyte lysate is then contacted with the biologically active substance to be incorporated into the erythrocyte. To reseal the membranes of the erythrocytes, the osmotic and/or oncotic pressure of the erythrocyte lysate is increased and the suspension of resealed erythrocytes is recovered.
[0024] In related U.S. Pat. Nos. 4,874,690 and 5,043,261 to Goodrich et al., a related technique involving lyophilization and reconstitution of red blood cells is disclosed. As part of the process of reconstituting the red blood cells, the addition of various polyanions, including IHP, is described. Treatment of the red blood cells according to the process disclosed results in a cell with unaffected activity. Presumably, the IHP is incorporated into the cell during the reconstitution process, thereby maintaining the activity of the hemoglobin.
[0025] In U.S. Pat. Nos. 4,478,824 and 4,931,276 to Franco et al., a second related method and apparatus is described for introducing effectively non-ionic agents, including IHP, into mammalian red blood cells by effectively lysing and resealing the cells. The procedure is described as the “osmotic pulse technique.” In practicing the osmotic pulse technique, a supply of packed red blood cells is suspended and incubated in a solution containing a compound which readily diffuses into and out of the cells, the concentration of the compound being sufficient to cause diffusion thereof into the cells so that the contents of the cells become hypertonic. Next, a trans-membrane ionic gradient is created by diluting the solution containing the hypertonic cells with an essentially isotonic aqueous medium in the presence of at least one desired agent to be introduced, thereby causing diffusion of water into the cells with a consequent swelling and an increase in permeability of the outer membranes of the cells. This “osmotic pulse” causes the diffusion of water into the cells and a resultant swelling of the cells which increase the permeability of the outer cell membrane to the desired agent. The increase in permeability of the membrane is maintained for a period of time sufficient only to permit transport of at least one agent into the cells and diffusion of the compound out of the cells.
[0026] Polyanions which may be used in practicing the osmotic pulse technique include pyrophosphate, tripolyphosphate, phosphorylated inositols, 2,3-diphosphoglycerate (DPG), adenosine triphosphate, heparin, and polycarboxylic acids which are water-soluble, and non-disruptive to the lipid outer bilayer membranes of red blood cells.
[0027] The osmotic pulse technique has several shortcomings including low yield of encapsulation, incomplete resealing, loss of cell content and a corresponding decrease in the life span of the cells. The technique is tedious, complicated and unsuited to automation. For these reasons, the osmotic pulse technique has had little commercial success.
[0028] Another method for encapsulating various biologically-active substances in erythrocytes is electroporation. Electroporation has been used for encapsulation of foreign molecules in different cell types, including IHP in red blood cells, as described in Mouneimne, et al., “Stable rightward shifts of the oxyhemoglobin dissociation curve induced by encapsulation of inositol hexaphosphate in red blood cells using electroporation,” FEBS, Vol. 275, No. 1, 2, pp. 117-120 (1990). Also, see U.S. Pat. No. 5,612,207.
[0029] Angiogenesis is the generation of new blood vessels into a tissue or organ and is related to oxygen tension in the tissues. Under normal physiological conditions, humans and animals undergo angiogenesis only in very specific, restricted situations. For example, angiogenesis is normally observed in wound healing, fetal and embryonal development, and formation of the corpus luteum, endometrium and placenta.
[0030] Angiogenesis is controlled through a highly regulated system of angiogenic stimulators and inhibitors. The control of angiogenesis is altered in certain disease states and, in many cases, pathological damage associated with the diseases is related to uncontrolled angiogenesis. Both controlled and uncontrolled angiogenesis are thought to proceed in a similar manner. Endothelial cells and pericytes, surrounded by a basement membrane, form capillary blood vessels. Angiogenesis begins with the erosion of the basement membrane by enzymes released by endothelial cells and leukocytes. Endothelial cells, lining the lumen of blood vessels, then protrude through the basement membrane. Angiogenic stimulants induce the endothelial cells to migrate through the eroded basement membrane. The migrating cells form a “sprout” off the parent blood vessel where the endothelial cells undergo mitosis and proliferate. The endothelial sprouts merge with each other to form capillary loops, creating a new blood vessel.
[0031] Persistent, unregulated angiogenesis occurs in many disease states, tumor metastases, and abnormal growth by endothelial cells. The diverse pathological disease states in which unregulated angiogenesis is present have been grouped together as angiogenic-dependent or angiogenic-associated diseases.
[0032] The hypothesis that tumor growth is angiogenesis-dependent was first proposed in 1971. (Folkman, New Eng. J. Med., 285:1182-86 (1971)). In its simplest terms, this hypothesis states: “Once tumor ‘take’ has occurred, every increase in tumor cell population must be preceded by an increase in new capillaries converging on the tumor.” Tumor ‘take’ is currently understood to indicate a prevascular phase of tumor growth in which a population of tumor cells occupying a few cubic millimeters volume, and not exceeding a few million cells, can survive on existing host microvessels. Expansion of tumor volume beyond this phase requires the induction of new capillary blood vessels. For example, pulmonary micrometastases in the early prevascular phase in mice would be undetectable except by high power microscopy on histological sections.
[0033] Angiogenesis has been associated with a number of different types of cancer, including solid tumors and blood-borne tumors. Solid tumors with which angiogenesis has been associated include, but are not limited to, rhabdomyosarcomas, retinoblastoma, Ewing's sarcoma, neuroblastoma, and osteosarcoma. Angiogenesis is also associated with blood-borne tumors, such as leukemias, any of various acute or chronic neoplastic diseases of the bone marrow in which unrestrained proliferation of white blood cells occurs, usually accompanied by anemia, impaired blood clotting, and enlargement of the lymph nodes, liver and spleen. It is believed that angiogenesis plays a role in the abnormalities in the bone marrow that give rise to leukemia tumors and multiple myeloma diseases.
[0034] One of the most frequent angiogenic diseases of childhood is the hemangioma. A hemangioma is a tumor composed of newly formed blood vessels. In most cases, the tumors are benign and regress without intervention. In more severe cases, the tumors progress to large cavernous and infiltrative forms and create clinical complications. Systemic forms of hemangiomas, hemangiomatoses, have a high mortality rate. Therapy-resistant hemangiomas exist that cannot be treated with therapeutics currently in use.
[0035] Another angiogenesis associated disease is rheumatoid arthritis. The blood vessels in the synovial lining of the joints undergo angiogenesis. In addition to forming new vascular networks, the endothelial cells release factors and reactive oxygen species that lead to pannus growth and cartilage destruction. Angiogenesis may also play a role in osteoarthritis. The activation of the chondrocytes by angiogenic-related factors contributes to the destruction of the joint. At a later stage, the angiogenic factors promote new bone growth. Therapeutic intervention that prevents the cartilage destruction could halt the progress of the disease and provide relief for persons suffering with arthritis.
[0036] Chronic inflammation may also involve pathological angiogenesis. Such diseases as ulcerative colitis and Crohn's disease show histological changes with the ingrowth of new blood vessels into inflamed tissues. Bartonelosis, a bacterial infection found in South America, can result in a chronic stage that is characterized by proliferation of vascular endothelial cells. Another pathological role associated with angiogenesis is found in atherosclerosis. The plaques formed within the lumen of blood vessels have been shown to have angiogenic stimulatory activity.
[0037] As mentioned above, several lines of evidence indicate that angiogenesis is essential for the growth and persistence of solid tumors and their metastases. Once angiogenesis is stimulated, tumors upregulate the production of a variety of angiogenic factors, including fibroblast growth factors (aFGF and bFGF) and vascular endothelial growth factor/vascular permeability factor (VEGF/VPF) [2,3].
[0038] The role of VEGF in the regulation of angiogenesis has been the object of intense investigation [5-10]. Whereas VEGF represents a critical, rate-limiting step in physiological angiogenesis, it appears to be also important in pathological angiogenesis, such as that associated with tumor growth [11]. VEGF is also known as vascular permeability factor, based on its ability to induce vascular leakage [13]. Several solid tumors produce ample amounts of VEGF, which stimulates proliferation and migration of endothelial cells, thereby inducing neovascularization [12,13]. VEGF expression has been shown to significantly affect the prognosis of different kinds of human cancer. Oxygen tension in the tumor has a key role in regulating the expression of VEGF gene. VEGF mRNA expression is induced by exposure to low oxygen tension under a variety of pathophysiological circumstances [13]. Growing tumors are characterized by hypoxia, which induces expression of VEGF and may also be a predictive factor for the occurrence of metastatic disease.
[0039] What is needed, therefore, is a substantially non-toxic composition and method that can regulate oxygen tension in the tissue, especially a tumor. In addition, what is needed is a simple and easily administered, preferably orally, composition that is capable of causing significant right shifts of the P 50 value for red blood cells.
SUMMARY OF THE INVENTION
[0040] The present invention provides a composition comprising the mixed calcium/sodium salt of inositol-tripyrophosphate (ITPP-Ca/Na) that is effective in treating diseases characterized by abnormal angiogenesis. The compositions and methods of the present invention have a distinct advantage over the prior art in that the compositions and methods of the present invention are substantially non-toxic and demonstrate improved solubility when compared to compositions in the prior art.
[0041] The present invention also comprises a pharmaceutical composition comprising the calcium/sodium salt of ITPP and a pharmaceutically acceptable adjuvant, diluent, carrier, or excipient thereof. In this pharmaceutical composition, the inositol tripyrophosphate is optimally myo-inositol 1,6:2,3:4,5 tripyrophosphate. In an alternate embodiment the composition may comprise the monocalcium tetrasodium salt of myo-inositol 1,6:2,3:4,5 tripyrophosphate.
[0042] The present invention also provides for substantially non-toxic methods of using the above compositions of ITPP-Ca/Na for increasing the regulated delivery of oxygen to tissues including tumors. For example, the regulation of vascular endothelial growth factor (VEGF) in a human or animal can be effected using ITPP-Ca/Na which has entered the red blood cell, thus lowering the affinity for oxygen of circulating erythrocytes. In an embodiment of the present invention, ITPP-Ca/Na can affect VEGF mRNA expression, protein concentration, and tumor cell proliferation. Also, a method of regulating VEGF expression, both in vitro and in vivo, using ITPP-Ca/Na is contemplated and therefore within the scope of the present invention.
[0043] The present invention further comprises methods for using the above compositions of ITPP-Ca/Na in pure hemoglobin and in red blood cells to deliver oxygen to solid tumors, to inhibit angiogenesis and to enhance radiation sensitivity of hypoxic tumors. The present invention is further directed to the use of ITPP-Ca/Na to enhance PO 2 in hypoxic tumors. ITPP-Ca/Na is an allosteric effector of hemoglobin and is capable of reducing hemoglobin's affinity for oxygen, which enhances the release of oxygen by hemoglobin. Upon cellular demand, ITPP-Ca/Na can inhibit VEGF expression in tumor cells and, thus, angiogenesis.
[0044] A disease characterized by undesirable angiogenesis or undesirable angiogenesis, as defined herein includes, but is not limited to, excessive or abnormal stimulation of endothelial cells (e.g. atherosclerosis), blood borne tumors, solid tumors and tumor metastasis, benign tumors, for example, hemangiomas, acoustic neuromas, neurofibromas, trachomas, and pyogenic granulomas, vascular malfunctions, abnormal wound healing, inflammatory and immune disorders, Bechet's disease, gout, or gouty arthritis, diabetic retinopathy and other ocular angiogenic diseases such as retinopathy of prematurity (retrolental fibroplasic), macular degeneration, corneal graft rejection, neovascular glaucoma and Osler Weber syndrome (Osler-Weber-Rendu disease). Cancers that can be treated by the present invention include, but is not limited to, breast cancer, prostrate cancer, renal cell cancer, brain cancer, ovarian cancer, colon cancer, bladder cancer, pancreatic cancer, stomach cancer, esophageal cancer, cutaneous melanoma, liver cancer, lung cancer, testicular cancer, kidney cancer, bladder cancer, cervical cancer, lymphoma, parathyroid cancer, penile cancer, rectal cancer, small intestine cancer, thyroid cancer, uterine cancer, Hodgkin's lymphoma, lip and oral cancer, skin cancer, leukemia or multiple myeloma.
[0045] An object of the invention is to provide a substantially non-toxic composition and method for treating cancer and other angiogenic disease states and conditions using ITPP-Ca/Na in an effective dose.
[0046] Another object of the invention is to provide a composition and method for enhancing oxygen delivery to hypoxic tumors using ITPP-Ca/Na in an effective dose.
[0047] Yet another object of the invention is to provide a composition and method for inhibiting angiogenesis using ITPP-Ca/Na in an effective dose.
[0048] A further object of the invention is to provide a composition and method for enhancing radiation sensitivity of hypoxic tumors using ITPP-Ca/Na in an effective dose.
[0049] It is yet another object of the invention to provide a composition and method of treating hypoxic tumors and diseases using ITPP-Ca/Na in an effective dose.
[0050] Another object of the invention is to provide a composition and method using ITPP-Ca/Na in an effective dose that can regulate oxygen tension in the tissue, especially a tumor.
[0051] A further object of the invention is to provide a simple and easily administered, preferably oral, composition that is capable of causing significant right shifts of the P 50 value for red blood cells using ITPP-Ca/Na in an effective dose.
[0052] These and other objects, features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 shows ITPP-Ca/Na loaded red blood cell suppression of HIF-1 induction, VEGF and angiogenesis of hypoxic endothelial cells in vitro.
[0054] FIG. 2 shows the potential of ITPP-Ca/Na as a dual action radiation sensitizer and angiogenesis inhibitor in pancreatic and rectal cancers.
[0055] FIG. 3 shows an agarose gel indicating the VEGF mRNA concentrations in tumors from control and ITPP drinking animals.
[0056] FIG. 4 show a Western blot assay of expressed VEGF in tumors of control and ITPP-treated Lewis Lung carcinoma (LLC) tumor-bearing animals.
[0057] FIG. 5 shows a synthesis scheme for synthesizing the monocalcium tetrasodium salt of myo-inositol 1,6:2,3:4,5 tripyrophosphate.
[0058] FIG. 6 shows an oxygen fixation curve for hemoglobin after incubation with ITPP-Ca4Na.
[0059] FIG. 7 shows the percent shift of the p50 of whole human blood after incubation with ITPP-Ca4Na.
DETAILED DESCRIPTION OF THE INVENTION
[0060] Compositions that are useful in accordance with the present invention include the mixed calcium/sodium salt of inositol-tripyrophosphate (ITPP-Ca/Na). ITPP exhibits anti-angiogenic and anti-tumor properties, and is useful in controlling angiogenesis-, or proliferation-related events, conditions or substances. As used herein, the control of an angiogenic-, or proliferation-related event, condition, or substance refers to any qualitative or quantitative change in any type of factor, condition, activity, indicator, chemical or combination of chemicals, mRNA, receptor, marker, mediator, protein, transcriptional activity or the like, that may be or is believed to be related to angiogenesis or proliferation, and that results from administering the composition of the present invention. Those skilled in the art will appreciate that the invention extends to other compositions or compounds in the claims below, having the described characteristics. These characteristics can be determined for each test compound using the assays detailed below and elsewhere in the literature.
[0061] Other such assays include counting of cells in tissue culture plates or assessment of cell number through metabolic assays or incorporation into DNA of labeled (radiochemically, for example 3 H-thymidine, or fluorescently labeled) or immuno-reactive (BrdU) nucleotides. In addition, antiangiogenic activity may be evaluated through endothelial cell migration, endothelial cell tubule formation, or vessel outgrowth in ex-vivo models, such as rat aortic rings.
[0062] When administered orally, ITPP exhibits anti-tumor and anti-proliferative activity with little or no toxicity. ITPP was tested for its ability to induce a decrease of the O 2 -affinity of hemoglobin measured as a shift of the P 50 value (P 50 at 50% saturation of hemoglobin). With murine hemoglobin and whole blood, P 50 shifts to higher PO 2 of up to 250% with hemoglobin and up to 40% with whole blood were observed.
[0063] The results obtained with ITPP in mice and pigs strongly suggest the possibility of its development as a therapeutic, due to its ability to enhance, in a regulated manner, oxygen delivery by red blood cells in the cases of blood flow impairment.
[0064] It has been found that pigs injected intravenously with ITPP-Na at a rate of 1 g/kg weight had beneficial properties associated with the introduction of ITPP-Na into their systems (as described in U.S. Provisional Patent Application 60/585,804, which is herein incorporated by reference in its entirety); however, the introduction of ITPP-Na also resulted in a number of adverse side effects. These side effects included flushing, an increase in the heart rate, and a decrease in the Ca 2+ plasma concentration. Therefore a less toxic form of ITPP that maintains a good solubility profile is needed.
[0065] ITPP, when administered orally, intravenously, or intraperitoneally, inhibits angiogenesis in growing tumors by enhancing PO 2 in the forming tumors. This invention further provides for methods of regulation of vascular endothelial growth factor (VEGF) in a human or animal, by administering to the human or animal an effective amount of ITPP. More particularly, this invention provides for dose-dependent effects of ITPP on VEGF mRNA and protein expressions in the LLC cell line. VEGF gene expression in tumor bearing C57BL/6 mice was assayed and the effects of ITPP-induced down regulation of VEGF have been determined and correlated with modulation of cell proliferation. This invention resulted in the development of methods to control VEGF mRNA expression, protein concentration, and tumor cell proliferation. The results of these studies indicate a strong correlation between dose-dependent ITPP-induced down regulation of VEGF and cellular proliferation and suggests that ITPP can reduce VEGF mediated tumor angiogenesis, as well as the rate of tumor cell proliferation. Thus, down-regulation of VEGF by ITPP decreases tumor cell proliferation.
[0066] The shifting of the P 50 value to higher O 2 -partial pressures inhibits the expression of the hypoxia gene encoding VEGF in the tumors. Expression of the hypoxia gene encoding VEGF is necessary for angiogenesis to be stimulated in tumors. If this does not occur, angiogenesis is seriously inhibited and new vessels are not formed in tumors.
[0067] The results obtained concerning VEGF expression suggests that oxygen partial pressure in tumors is elevated upon administration of ITPP, as this elevation is the cause of inhibition of expression of this hypoxia gene. This observation raises a very important question, namely, whether this enhancement of PO 2 may act as a powerful radiosensitizer of cancer cells. Oxygen is a very potent radiosensitizer and, if indeed PO 2 in the tumors is enhanced by ITPP, this may have major consequences in enhancing the efficacy of radiation therapy of cancer.
[0068] ITPP is a potential significant adjuvant in the therapy of solid tumors as inhibitor of angiogenesis on one hand, and as a radiosensitizer on the other.
[0069] It is known that medial temporal oxygen metabolism is markedly affected in patients with mild-to-moderate Alzheimer's disease. This measure substantiated the functional impairment of the medial temporal region in Alzheimer's disease. It also known that mean oxygen metabolism in the medial temporal, as well as in the parietal and lateral temporal cortices is significantly lower in the patients that are shown to have Alzheimer's disease than in control groups without Alzheimer's disease (see Ishii et al., J. Nucl Med. 37(7):1159-65, July 1996, which is herein incorporated by reference in its entirety). Thus, one potential means of treating patients shown to have Alzheimer's disease is to increase oxygen across the blood brain barrier. One method of doing so would be to use an allosteric effector of hemoglobin such as treatment with ITPP, such as with the calcium/sodium salt of ITPP.
[0070] The use of ITPP, such as with the calcium/sodium salt of ITPP, may also help in the treatment of a variety of vascular diseases associated with various forms of dementia. Because the brain relies on a network of vessels to bring it oxygen-bearing blood, if the oxygen supply to the brain fails, brain cells are likely to die and this can cause symptoms of vascular dementia. These symptoms can occur either suddenly, following a stroke, or over time through a series of small strokes. Thus, one potential means of treating patients with vascular diseases associated with various forms of dementia is to increase the oxygen available to affected areas such as across the blood brain barrier. One method of doing so would be to use an allosteric effector of hemoglobin such as treatment with ITPP, such as with the calcium/sodium salt of ITPP.
[0071] Moreover, treatment of an individual with an allosteric effector of hemoglobin such as the calcium/sodium salt of ITPP may have beneficial effects for both stroke victims and osteoporosis. Although stroke and the bone-thinning disease osteoporosis are usually thought of as two distinct health problems, it has been found that there may be a connection between them. Patients who survive strokes are significantly more likely to suffer from osteoporosis, a disease that puts them at high risk for bone fractures. Often, the fractures in stroke patients occur on the side of the body that has been paralyzed from the stroke.
[0072] It is known that a stroke occurs when the supply of blood and oxygen to the brain ceases or is greatly reduced. If a portion of the brain loses its supply of nutrient-rich blood and oxygen, the bodily functions controlled by that part of the brain (vision, speech, walking, etc.) are impaired. Annually, more than 500,000 people in the United States suffer strokes and 150,000 of those people die as a result thereof. One means of increasing oxygen flow to the brain is by use of an allosteric effector of hemoglobin such as treatment with the calcium/sodium salt of ITPP. Accordingly, a potential method of treating individuals who might potentially suffer stroke or osteoporosis is by treatment of an individual with, for example, the calcium/sodium salt of ITPP.
[0073] Also contemplated by the present invention are implants or other devices comprised of the compounds or drugs of ITPP, or prodrugs thereof, where the drug or prodrug is formulated in a biodegradable or non-biodegradable polymer for sustained release. Non-biodegradable polymers release the drug in a controlled fashion through physical or mechanical processes without the polymer itself being degraded. Biodegradable polymers are designed to gradually be hydrolyzed or solubilized by natural processes in the body, allowing gradual release of the admixed drug or prodrug. The drug or prodrug can be chemically linked to the polymer or can be incorporated into the polymer by admixture. Both biodegradable and non-biodegradable polymers and the process by which drugs are incorporated into the polymers for controlled release are well known to those skilled in the art. Examples of such polymers can be found in many references, such as Brem et al., J. Neurosurg 74: pp. 441-446 (1991), which is herein incorporated by reference in its entirety. These implants or devices can be implanted in the vicinity where delivery is desired, for example, at the site of a tumor.
[0074] In addition to the compounds of the present invention, the pharmaceutical composition of this invention may also contain, or be co-administered (simultaneously or sequentially) with, one or more pharmacological agents of value in treating one or more disease conditions referred to hereinabove.
[0075] A person skilled in the art will be able by reference to standard texts, such as Remington's Pharmaceutical Sciences 17 th edition, to determine how the formulations are to be made and how these may be administered.
[0076] In a further aspect of the present invention there is provided use of compounds of ITPP, such as ITPP-Ca/Na or prodrugs thereof, according to the present invention for the preparation of a medicament for the prophylaxis or treatment of conditions associated with angiogenesis or accelerated cell division or inflammation.
[0077] In a further aspect of the present invention there is provided a pharmaceutical composition comprising compounds of ITPP, such as ITPP-Ca/Na or prodrugs thereof, according to the present invention, together with a pharmaceutically acceptable carrier, diluent, adjuvant or excipient.
[0078] The pharmaceutical composition may be used for the prophylaxis or treatment of conditions associated with angiogenesis or accelerated cell division or inflammation, for treatment of Alzheimer's disease, treatment of stroke and/or osteoporosis.
[0079] In a still further aspect of the present invention there is provided a method of prophylaxis or treatment of a condition associated with angiogenesis or accelerated or increased amounts of cell division, hypertrophic growth, or inflammation, said method including administering to a patient in need of such prophylaxis or treatment an effective amount of compounds of ITPP, such as ITPP-Ca/Na or prodrugs thereof, according to the present invention, as described herein. It should be understood that prophylaxis or treatment of said condition includes amelioration of said condition.
[0080] By “an effective amount” as referred to in this specification, it is meant a therapeutically or prophylactically effective amount. Such amounts can be readily determined by an appropriately skilled person, taking into account the condition to be treated, the route of administration and other relevant factors. Such a person will readily be able to determine a suitable dose, mode and frequency of administration. “Individual” as referred to in this application refers to any animal that may be in need of treatment for a given condition. “Individual” includes humans, other primates, household pets, livestock, rodents, other mammals, and any other animal(s) that may typically be treated by a veterinarian.
[0081] The compositions described above can be provided as physiologically acceptable formulations using known techniques, and these formulations can be administered by standard routes. In general, the combinations may be administered by the topical, oral, rectal, intraperitoneal or parenteral (e.g., intravenous, subcutaneous or intramuscular) route. In addition, the combinations may be incorporated into polymers allowing for sustained release, the polymers being implanted in the vicinity of where delivery is desired, for example, at the site of a tumor, or into an a cavity or blood vessel that will lead to easy delivery to the place to be treated. The dosage of the composition will depend on the condition being treated, the particular derivative used, and other clinical factors such as weight and condition of the patient and the route of administration of the compound. However, for oral administration, a recommended dosage is in the range of 0.1 to 5.0 g/kg/day. A dosage for oral administration is in the range of 0.5 to 2.0 g/kg/day or alternatively, about 0.5 to about 1.5 g/kg/day. In an alternate embodiment, a dosage for oral administration is in the range of about 0.80 to 1.0 g/kg/day or alternatively, about between 0.9 to 1.1 g/kg/day.
[0082] The formulations in accordance with the present invention can be administered in the form of tablet, a capsule, a lozenge, a cachet, a solution, a suspension, an emulsion, a powder, an aerosol, a suppository, a spray, a pastille, an ointment, a cream, a paste, a foam, a gel, a tampon, a pessary, a granule, a bolus, a mouthwash, or a transdermal patch.
[0083] The formulations include those suitable for oral, rectal, nasal, inhalation, topical (including dermal, transdermal, buccal and sublingual), vaginal, parenteral (including subcutaneous, intramuscular, intravenous, intraperitoneal, intradermal, intraocular, intratracheal, and epidural) or inhalation administration. The formulations may conveniently be presented in unit dosage form and may be prepared by conventional pharmaceutical techniques. Such techniques include the step of bringing into association the active ingredient and a pharmaceutical carrier(s) or excipient(s). In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided solid carriers or both, and then, if necessary, shaping the product.
[0084] Formulations contemplated as part of the present invention include nanoparticles formulations made by methods disclosed in U.S. patent application Ser. No. 10/392,403 (Publication No. 2004/0033267) which is hereby incorporated by reference in its entirety. By forming nanoparticles, the compositions disclosed herein are shown to have increased bioavailability. Preferably, the particles of the compounds of the present invention have an effective average particle size of less than about 2 microns, less than about 1900 nm, less than about 1800 nm, less than about 1700 nm, less than about 1600 nm, less than about 1500 nm, less than about 1400 nm, less than about 1300 nm, less than about 1200 nm, less than about 1100 nm, less than about 1000 nm, less than about 900 nm, less than about 800 run, less than about 700 nm, less than about 600 nm, less than about 500 nm, less than about 400 nm, less than about 300 nm, less than about 250 nm, less than about 200 nm, less than about 150 nm, less than about 100 nm, less than about 75 nm, or less than about 50 nm, as measured by light-scattering methods, microscopy, or other appropriate methods well known to those of ordinary skill in the art.
[0085] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil emulsion, etc.
[0086] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing, in a suitable machine, the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, preservative, surface-active or dispersing agent. Molded tablets may be made by molding, in a suitable machine, a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide a slow or controlled release of the active ingredient therein.
[0087] Formulations suitable for topical administration in the mouth include lozenges comprising the ingredients in a flavored basis, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert basis such as gelatin and glycerin, or sucrose and acacia; and mouthwashes comprising the ingredient to be administered in a suitable liquid carrier.
[0088] Formulations suitable for topical administration to the skin may be presented as ointments, creams, gels and pastes comprising the ingredient to be administered in a pharmaceutically acceptable carrier. A preferred topical delivery system is a transdermal patch containing the ingredient to be administered.
[0089] Formulations for rectal administration may be presented as a suppository with a suitable base comprising, for example, cocoa butter and/or a salicylate.
[0090] Formulations suitable for nasal administration, wherein the carrier is a solid, include a coarse powder having a particle size, for example, in the range of 20 to 500 microns which is administered in the manner in which snuff is taken; i.e., by rapid inhalation through the nasal passage from a container of the powder held close up to the nose. Suitable formulations, wherein the carrier is a liquid, for administration, as for example, a nasal spray or as nasal drops, include aqueous or oily solutions of the active ingredient.
[0091] Formulations suitable for vaginal administration may be presented as pessaries, tampons, creams, gels, pastes, foams or spray formulations containing, in addition to the active ingredient, ingredients such as carriers as are known in the art to be appropriate.
[0092] Formulation suitable for inhalation may be presented as mists, dusts, powders or spray formulations containing, in addition to the active ingredient, ingredients such as carriers as are known in the art to be appropriate.
[0093] Formulations suitable for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example, sealed ampules and vials, and may be stored in freeze-dried (lyophilized) conditions requiring only the addition of a sterile liquid carrier, for example, water for injections, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kinds previously described.
[0094] Preferred unit dosage formulations are those containing a daily dose or unit, daily sub-dose, as herein above recited, or an appropriate fraction thereof, of the administered ingredient.
[0095] It should be understood that in addition to the ingredients, particularly those mentioned above, the formulations of the present invention may include other agents conventional in the art having regard to the type of formulation in question, for example, those suitable for oral administration may include flavoring agents or other agents to make the formulation more palatable and more easily swallowed.
Experimental
[0096] For the in vitro experiments, ITPP was dissolved in deionized water, pH was adjusted at pH 7 and, for incubation with whole blood, the osmolarity of the ITPP solutions was adjusted with glucose to 270-297 mOsM. Mixtures of hemoglobin and ITPP were measured with a HEMOX analyzer (PD Marketing, London) immediately after mixing. Red blood cells were incubated with ITPP for 1 hour at 37° C. Following incubation, the cells were washed 3 times with Bis-Tris-buffer (pH=7.0) and then used for P 50 measurement.
[0097] In experiments conducted in vivo in which ITPP was administered orally, a significant shift of the P 50 value of circulating RBCs was observed. ITPP was dissolved in drinking water at a 20 g/L-concentration (0.27 mM, pH˜7.0.) and offered for drinking ad libitum.
[0098] The following examples illustrate but do not limit the invention. Thus, the examples are presented with the understanding that modifications may be made and still be within the spirit and scope of the invention.
EXAMPLE 1
Effectiveness of the Mixed Calcium Sodium Salt of myo-Inositol Tripyrophosphate
[0099] When myo-inositol tripyrophosphate-sodium salt (ITPP-Na) is mixed with CaCl 2 , a mixture of ITPP-Na (myo-inositol tripyrophosphate-sodium salt) and ITPP-Ca (myo-inositol tripyrophosphate-calcium salt) is obtained. This mixture, when added to free hemoglobin or to whole blood induces a P 50 shift of 170% and 25%, respectively as shown in Tables 2 and 3 below. Please see the results in Tables 2 and 3 for compound 15. The compounds in Tables 2 and 3 are as follows: 4 is the pyridinium salt of ITPP, 5 is the sodium salt of ITPP (i.e., ITPP-Na), 7 is the N,N-dimethylcyclohexyl ammonium salt of ITPP, 11 is the cycloheptyl ammonium salt of ITPP, 12 is the cyclooctyl ammonium salt of ITPP, 13 is the piperazinium salt of ITPP, 14 is the tripiperazinium salt of ITPP, and 15 is the calcium salt of ITPP (i.e., ITPP-Ca).
[0100] In Tables 2 and 3, the effectiveness of all of the salts of ITPP regarding their ability to act as allosteric effectors of hemoglobin can be seen. The sodium salt and the calcium salt of ITPP appear to be the best allosteric effectors for both free hemoglobin (Table 2) and in whole blood (Table 3). However, pigs injected intravenously with ITPP-Na at a rate of 1 g/kg weight resulted in a number of adverse side effects. The intravenous injection of pigs with ITPP-Na resulted in flushing, an increase in the heart rate, and a decrease in the Ca 2+ plasma concentration from 2.38 mmol/L to 1.76 mmol/L.
[0101] Administration of the mixture of the sodium and calcium salt of ITPP, at the same dosage did not induce any of the cited effects and the Ca 2+ plasma concentration stayed unchanged at 2.38 mmol/L.
[0102] FIG. 1 shows the ability of ITPP-Ca/Na loaded red blood cells suppression of HIF-1 induction, VEGF and angiogenesis of hypoxic endothelial cells in vitro. FIG. 2 demonstrates the potential of ITPP-Ca/Na as a radiation sensitizer and as an angiogenesis inhibitor in pancreatic and rectal cancers.
[0000]
TABLE 2
P 50 values of free Hb after incubation with
compounds 4, 5, 7, 11-14 and 15, in vitro
P 50 (Torr)
P 50 (Torr)
P 50 increase
Compound
Free Hb
Hb + compound
(%) + SD
4
(H) 15.3
31.6
107 ± 22
(M) 25.0
50.0
100 ± 18
5
(H) 15.3
49.8
225 ± 19
(M) 24.9
69.7
180 ± 25
(P) 22.0
68.1
209 ± 39
7
(M) 24.9
45.1
81 ± 15
11
(M) 24.9
43.8
71 ± 3
12
(M) 24.9
30.6
23 ± 5
13
(M) 23.4
67.7
189 ± 43
14
(M) 23.4
82.9
254 ± 49
15
(H) 123
33.1
170 ± 32
(M) 26.9
61.9
130 ± 30
H = human; M = murine; P = porcine free Hb. Concentration of the compound solution was 60 mM; means of P 50 shifts in % are shown. SD = standard deviation. Compounds 4, 7, 11, 12, 14 and 15: three P 50 values each were used for the calculation of means; compound 5: with human blood: five values, murine blood: ten values and porcine blood; three values were used for the calculation of the means of P 50 shifts in %.
[0000]
TABLE 3
P 50 values of whole blood after incubation with
compounds 4, 5, 7, 11-14 and 15, in vitro
P 50 (Torr)
P 50 (Torr)
compound +
P 50 increase
Compound
whole blood
whole blood
(%) + SD
4
(H) 22.1
24.3
10 ± 4
(M) 37.9
42.7
13 ± 2
5
(H) 22.1
30.8
39 a ± 5
(P) 31.6
44.2
40 a ± 3
(M) 36.7
47.4
29 b ± 3
7
(M) 40.1
52.0
30 ± 3
11
(M) 37.9
45.5
20 ± 2
12
(M) 37.9
41.3
9 ± 1
13
(M) 37.9
41.7
10 ± 2
14
(M) 39.2
41.9
7 ± 1
15
(M) 39.2
42.3
8 ± 2
(H) 24.8
31.0
25 ± 3
(M) 40.1
55.3
38 a ± 4
H = human; M = murine; P = porcine whole blood. Compound concentrations: 30 mM; means of (four single values) P 50 shifts □ SD are shown.
a Compound concentration: 60 mM.
b Compound concentration: 4 mM.
EXAMPLE 2
Effect of in vivo Lowering of Hemoglobin's Affinity for O 2 by ITPP on Intratumoral PO 2 Angiogenesis and Expression of VEGF mRNA
[0103] ITPP, when administered orally, intravenously, or intraperitoneally, inhibits angiogenesis in growing tumors by enhancing the PO 2 in the forming tumors. Thirty (30) C57BL/6 mice received 20 g/L of ITPP orally until the P 50 value showed a shift of at least 20% above the control value. Thereafter, all animals received 1×10 6 Lewis Lung carcinoma (LLC) cells, injected in the dorsal cavity. At different time points, the VEGF mRNA were assayed by RT-PCR in the tumors growing in both groups of mice.
[0104] Tumor tissue samples were ground in a RIPA lysis buffer (1% Nonidet p-40 detergent, 50mM Tris pH 8.0, 137 mM NaCl, 10% glycerol) supplemented with protease inhibitor cocktail (Roche, Reinach, Switzerland). After centrifugation for 10 minutes at 4° C. and 12,000 g, protein concentrations of tissue extracts were determined according to the Bradford method. Detergent soluble protein samples (10 mg) were separated by size on a SDS-PAGE in 10% acrylamide gels and transferred to nitrocellulose membrane (Protran BA 85, Schleicher and Schuell, Dassel, Germany). Membranes were blocked for 3 hours at room temperature in 10% skim milk in Tris buffer saline containing 0.1% Tween, before an overnight incubation at 4° C. with rabbit polyclonal antibodies recognizing human, mouse and rat vascular endothelial growth factor (VEGF A-20, sc-152, Santa Cruz Biotechnology, Santa Cruz, Calif.) at a dilution of 1:200. Membranes were then probed for primary antibody with anti-rabbit (1:16,000) peroxidase conjugates (Sigma-Aldrich, L'Isle d'Abeau Chesnes, France) for 60 minutes at room temperature. The resulting complexes were visualized by enhanced chemiluminescence autoradiography (Amersham Pharma Biotech, Orsay, France).
[0105] There was a difference in the level of mRNA of the VEGF gene in both groups. FIG. 3 shows an agarose gel indicating the VEGF mRNA concentrations in tumors from control and ITPP drinking animals. The RT-PCR agarose gel assay of VEGF mRNAs from tumor tissue taken from 2 mice each on day 15 after inoculation of LLC cells (track 1: controls, track 2: ITPP treated animals) and day 30 after inoculation (track 3: control animals, track 4: ITPP treated animals). FIG. 4 shows the Western blot assay of the expressed VEGF in tumors of control and ITPP-treated LLC tumor-bearing animals.
[0106] Quantification of the gel assays indicated a reduction by a factor of 10,000 of the amount of VEGF mRNAs detected in the tumors of animals having received ITPP, at day 9 and then, while differences remain between treated and untreated animals, they tend to decrease. This indicates that ITPP taken up by circulating red blood cells significantly increases tumor PO 2 .
EXAMPLE 3
Method of Synthesizing Monocalcium Tetrasodium myo-Inositol Tripyrophosphate
Materials:
[0000]
1. myo-Inositol hexakisphosphate dodecasodium salt (Product Number: P0109, Sigma).
2. Dicyclohexylcarbodiimide (Product Number: D80002, Aldrich).
3. Triethylamine (Product Number: 15791, Acros)
4. Dowex 50Wx8 hydrogen form (Product Number: 217506, Aldrich).
5. Ca(OH) 2 (Product Number: 239232, Aldrich).
6. NaOH (Product Number: 1040017, Sds).
7. Acetonitrile (Product Number: 34851, Aldrich).
8. Deionized Water.
Procedure:
[0115] The following synthesis scheme is shown in FIG. 5 . Dowex 50WX8-200 ion exchange resin (800 g) was washed with water until the elute was colorless. myo-Inositol hexakisphosphate dodecasodium salt (note-1) (100 g, 0.108 mol, 1.0 eq) was added portionwise (10 g/portion in about 45 minutes) to 500 mL of water. Each portion was dissolved with stirring at room temperature (23° C.) before the next portion was added. This solution was then passed through the column containing the above washed Dowex 50WX8-200 ion exchange resin and eluted with water (4×200 mL) to obtain the free phytic acid (note-2). To the combined acidic fractions, triethylamine (400 mL, 2.87 mol, 26.5 eq, about twice the theoretical quantity) was added over 1 to 2 minutes at room temperature (23 ° C.) and the mixture was stirred vigorously for 15 minutes (note-3). Then the solvent was evaporated on a rotary evaporator (60° C., 68-22 mbar) (note-4) and the residue was dried under high vacuum for 1 hr at room temperature (23° C.) to give the hexatriethylammonium myo-inositol hexakisphosphate (note-5).
[0116] To this hexatriethylammonium myo-inositol hexakisphosphate dissolved in water (800 mL), dicyclohexylcarbodiimide (142 g, 0.68 mol, 6.3 eq) dissolved in acetonitrile (1600 mL) was added at once and the mixture was refluxed for 12 h (note-6). One more equivalent of dicyclohexylcarbodiimide (22 g, 0.108 mol, 1.0 eq) dissolved in acetonitrile (40 mL) was added and refluxed for further 6 h (note-7). The mixture was cooled to room temperature (23° C.) and the dicyclohexylurea formed was filtered through a sintered funnel (note-8) and washed with water (3×200 mL). The filtrate was evaporated on a rotary evaporator (60° C., 68-22 mbar) and dried under high vacuum at room temperature (23° C.) (note-9). The resulting sticky syrupy residue was redissolved in 400 mL of water to remove all dicyclohexylurea that had remained dissolved in acetonitrile, filtered through a sintered funnel (note-8), and washed with water (2×100 mL). The filtrate was evaporated on a rotary evaporator (60° C., 68-22 mbar) and dried under high vacuum at room temperature (23° C.). The resulting residue was redissolved in 200 mL of water to remove any further dicyclohexylurea that had remained dissolved in solution, filtered through a sintered funnel (note-8), and washed with water (2×100 mL). The filtrate was evaporated on a rotary evaporator (60° C., 68-22 mbar) and dried under high vacuum at room temperature (23° C.) affording hexatriethylammonium myo-inositol 1,6:2,3:4,5 trispyrophosphate (note-10).
[0117] This hexatriethylammonium myo-inositol 1,6:2,3:4,5 trispyrophosphate salt was dissolved in 400 mL of water, passed through a column (note-11) containing prewashed Dowex 50WX8-200 (400 g) ion exchange resin and eluted with water (4×100 mL) (note-12). To the combined acidic fractions was immediately added solid Ca(OH) 2 (5.56 g, 0.075 mol, 1.0 eq) followed by addition of a NaOH solution [(12.0 g, 0.300 mol, 4.0 eq) in 25 mL of water)] at room temperature (23° C.) (note-13). Then the pH of the reaction mixture was carefully adjusted to around 6.99 with a solution of 1:4 Ca(OH) 2 :NaOH (1.5 g of Ca(OH) 2 and 3.23 g of NaOH in 1500 mL of water, ˜1385 mL brought the pH to ˜6.99) (note-14). Finally, the solvent was evaporated on a rotary evaporator (60° C., 68-22 mbar) and dried under high vacuum at room temperature (23° C.) to yield the monocalcium tetrasodium myo-inositol 1,6:2,3:4,5 trispyrophosphate, ITPP Ca4Na (77.2 g, 97%) as a white solid.
[0118] The compound obtained has been characterized by proton and phosphorous-31 NMR spectroscopy, mass spectroscopy, elemental analysis, cation determination by atomic absorption and water content. It contains less than 2% other phosphorous compounds. Elemental analysis (ICP atomic absorption): P 20%; Ca 4.2%; Na 10.3% (calc.: P 25.4%; Ca 5.5%; Na 12.6%). Water content: about 18-23% depending on drying conditions.
Notes:
[0000]
Note-1. Purity checked in-house by 1 H and 31 P NMR (>98%), as well as HPLC, elemental analysis and atomic absorption for cation determination.
Note-2. Collect the elutes which are acidic (pH paper). When all phytic acid is eluted, the elute becomes neutral.
Note-3. Addition of triethylamine generates some heat. Add progressively.
Note-4. Lower temperature can be used if evaporation can be achieved with the equipment available.
Note-5. Purity and characterization was checked by 1 H and 31 P NMR.
Note-6. Reflux temperature was about 80° C. Heated with a mantle.
Note-7. After 12 h, more than 98% product has been formed. Addition of more dicyclohexylcarbodiimide led to >99% product formation.
Note-8. The porosity of the sintered funnel used was 4 and this will effectively filter off the dicyclohexylurea byproduct.
Note-9. Thorough drying is necessary in order to be able to remove all the remaining dicyclohexylurea byproduct.
Note-10. Characterized by 1 H and 31 P NMR, purity>99%.
Note-11. Two typical procedures are for instance:
Procedure 1:
[0130] The column frit porosity was 1. The diameter of the column was 8 cm and the length of the Dowex bed was 9.5 cm. The solution was eluted first in 15 minutes without any pressure and then the washings under some pressure were eluted within 5 minutes.
Procedure 2:
[0131] The column frit porosity was 2. The diameter of the column was 6 cm and the length of the Dowex bed was 16.5 cm. The solution was eluted first in 45 minutes without any pressure and then the washings under some pressure were eluted within 5-10 minutes.
[0132] On the basis of numerous preparations, the following is recommended:
[0133] a) a column frit porosity of 1.
[0134] b) a Dowex column with a height/diameter ratio of 1.5-2.0, so that the elution time be less than 30 minutes. If the elution is too slow then flush with some pressure.
Note-12. CAUTION: As the myo-inositol 1,6:2,3:4,5 trispyrophosphate free acid may hydrolyse after standing for a long time at low pH (<1.0), the pH should be adjusted quickly to about 3-4 in order to avoid any such hydrolysis. Check then for absence of triethylamine signals in 1 H NMR (4-1 ppm) and for absence of phosphorous signals around 2-4 ppm. In the unlikely case that the 1 H NMR shows the presence of triethylamine, the whole solution has to be passed again over a fresh Dowex-H + in order to remove it. It is very important that there be no triethylamine left, as it would remain in the final material. Note-13. It is very important to add first solid Ca(OH) 2 and make sure that it is completely dissolved. After addition of the NaOH solution, the pH of the reaction mixture was ˜1.6. The total amount of Ca(OH) 2 :NaOH required to neutralize the reaction mixture to pH ˜6.9 was ˜6.9:14.9 g, respectively. In order to minimize the amount of 1:4 Ca(OH) 2 :NaOH solution required at the end (and reduce the final volume), add initially 6.3 g of solid Ca(OH) 2 followed by 13.6 g of NaOH (in 25 mL of water). Thereafter, the amount of 1:4 Ca(OH) 2 :NaOH solution required to bring the pH to 6.9-7.0 will be significantly reduced. Note-14. The 1:4 Ca(OH) 2 :NaOH solution should be freshly prepared and well closed; otherwise, CO 2 from the atmosphere will be absorbed and insoluble materials will be formed. Adjust the pH of the solution close to 7 and do not go beyond 7.
EXAMPLE 4
Biological Activity of the Monocalcium Tetrasodium Salt of myo-Inositol Tripyrophosphate (ITPP-Ca4Na)
[0138] ITPP-Ca4Na acts as a powerful effector of hemoglobin shifting the oxygen fixation curves to the right, with respect to the natural effector bisphosphoglycerate. The p50 values increase with concentration as show in FIGS. 6 and 7 . In FIG. 6 , hemoglobin is incubated (at concentrations up to 100 mM final) with ITPP Ca4Na, for 1 hour at 37° C. and measured by TCS-hemox analyzer for p50 shifts. In FIG. 7 , whole human blood was incubated (at concentrations up to 120 mM final) with ITPP Ca4Na, for 1 hour 37° C. and measured by TCS-hemox analyzer for p50 shifts.
EXAMPLE 5
Method of Preparing Monocalcium Tetrasodium Salt of Inositol Tripyorphosphate by Admixture
Composition
[0139] Final formulation will contain sodium salt of inositol tripyrophosphate (ITPP-Na) at a concentration of 105 mg/ml and calcium chloride dihydrate at a concentration of 15.7 mg/ml, corresponding to a Ca:Na molar ratio of 0.75 to yield a monocalcium tetrasodium inositol tripryrophosphate solution.
Preparation
[0140] The monocalcium tetrasodium ITTP solution will be prepared by adding a measured volume of 37.5% stock solution of ITPP-NA to a measured volume of sterile water for injection, followed by slow addition of a measured volume of 10% CaCl 2 .2H 2 O solution, with stirring.
37.5% ITPP-Na Stock Solution
[0141] For every 100 ml of stock solution required, dissolve 37.5 grams of ITPP-Na (on a pure weight basis, corrected for water content and impurities) in 75 ml of sterile water for injection. Adjust the pH to 7.5 using IN NaOH. Bring final volume to 100 with additional sterile water for injection.
10% CaCl 2 solution
For every 100 ml of stock solution required, dissolve 10 grams of CaCl 2 .2H 2 O in sterile water for injection and bring to a final total volume of 100 ml.
Monocalcium Tetrasodium ITPP Solution
[0142] For every 100 ml of monocalcium tetrasodium ITPP solution required, add 56.2 ml of sterile water for injection to an appropriate mixing vessel. Add 28.1 ml of 37.5% ITPP-Na stock solution with constant mixing. Follow with the slow addition of 15.7 ml of the 10% CaCl2 stock solution, with constant mixing.
Storage
[0143] Store monocalcium tetrasodium ITPP solution at approximately 5° C. until use, and use the test article solution within 24 to 72 hours of preparation.
Proposed Method for Admixing for use in Clinical Pharmacy
[0144] ITTP-Na Sterile Solution for injection will be supplied in single use, 10 ml vials containing 375 mg/ml of ITTP-Na (on a pure weight basis). 10% CaCl 2 Injection, USP, and Sterile Water for Injection will be purchased from existing manufacturers.
For every 100 ml of dosing solution required, 56.2 ml of Sterile Water for Injection will be added to an infusion bag. This will be followed by addition of 28.1 ml of ITPP-Na Sterile Solution for Injection with constant mixing. Then 15.7 ml of the 10% CaCl2 Injection, USP, will be added with constant mixing. The dosing solution will be administered through an in-line 0.2 micron filter.
Storage
[0145] If not to be used immediately, the final dosing solution will be stored at approximately 5° C. until use. It should be used within 24 to 72 hours of preparation
[0146] Having described the invention with reference to particular compositions, method for detection, and source of activity, and proposals of effectiveness, and the like, it will be apparent to those of skill in the art that it is not intended that the invention be limited by such illustrative embodiments or mechanisms, and that modifications can be made without departing from the scope or spirit of the invention, as defined by the appended claims. It is intended that all such obvious modifications and variations be included within the scope of the present invention as defined in the appended claims. It should be understood that any of the above described one or more elements from any embodiment can be combined with any one or more element in any other embodiment. Moreover, when a range is mentioned, it should be understood that it is contemplated that any real number that falls within the range is a contemplated end point. For example, if a range of 0.9 and 1.1 g/kg is given, it is contemplated that any real number value that falls within that range (for example, 0.954 to 1.052 g/kg) is contemplated as a subgenus range of the invention, even if those values are not explicitly mentioned. All references referred to herein are incorporated by reference in their entireties. Finally, the above description is not to be construed to limit the invention but the invention should rather be defined by the below claims.
REFERENCES
[0000]
1. Fylaktakidou, K., Lehn, J.-M., Greferath, R., and Nicolau, C. (2004) Bioorg. Med. Chem. Lett (submitted)
2. Kim K J, Li B, Winer J, Armanini M, Gillett N, Phillips B E, Ferrara N (1993) Nature 362, 841-844.
3. Kandel J, Bossy-Wetzel E, Radvanyi F, Klagsbrun M, Folkman J, Hanahan D (1991) Cell 66, 1095-1104.
4. O'Reilly M S, Boehm T, Shing Y, Fukai N, Vasios G, Lane W S, Flynn B, Birkhead J R. Olsen B R, Folkman J (1997) Cell 88, 277-285.
5. Good D J, Polverini P J, Rastinejad F, Le Beau mm, Lemons R S, Frazier W A, Bouck N P. (1990) Proc Natl Acad Sci USA 87, 6624-6628.
6. O'Reilly M S, Holmgren L, Shing Y, Chen C, Rosenthal R. A, Moses M, Lane W S, Cao Y, Sage E H, Folkman J (1994) Cell 79, 3 15-328.
7. Chen C, Parangi S, Tolentino M J, Folkman J. (1995) Cancer Res. 55, 4230-4233.
8. Ferrara N. (2002) Nat. Rev. Cancer 2, 795-803.
9. Ferrara N, Davis-Smyth T (1997) Endocr Rev. 18, 4-25.
10. Ferrara N, Gerber H P, LeCouter J. (2003) Nat Med. 9, 669-676.
11. Fontanini G, Vignati S, Boldrini L, Chine S, Silvestri V, Lucchi M, Mussi A, Angeletti C A, Bevilacqua G. (1997) Clin Cancer Res. 3, 861-865.
12. Dory, Porat R, Keshet E. (2001) Am J Physiol Cell Physiol. 280, C1367-1374.
13. Brizel D M, Scully S P, Harrelson J M, Layfield U, Bean J M, Prosnitz L R, Dewhirst M W (1996) Cancer Res. 56, 94 1-943.
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The present invention relates to mixed calcium/sodium salt of inositol tripyrophosphate, methods of preparing and methods of use. The mixed calcium/sodium salt may be a monocalcium tetrasodium salt of inositol tripyrophosphate. Methods of use include administering the above salts in an effective amount to treat diseases caused by hypoxia or other conditions associated with inadequate function of the lungs or circulatory system, such as various types of cancer and Alzheimer's disease.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 10-2010-0008138, filed with the Korean Intellectual Property Office on Jan. 28, 2010, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a scintillator of a scintillation detector that detects high energy particles and a method of binding a scintillator in medical diagnostic imaging equipment, more specifically to a scintillator that emits light by detecting high energy particles generated by an object examined by a common medical diagnostic imaging equipment and a scintillation detector and medical diagnostic imaging equipment using such a scintillator.
[0004] 2. Background Art
[0005] Medical diagnostic imaging equipment commonly includes computed tomography (CT), magnetic resonance imaging (MRI) and the like. Such imaging technologies are increasingly used for a more accurate examination by spotting a region having growing tissues to identify a thrombus, a scar, dead cancer tissue and the like from living tissues. In the medical device industry, which has recently attracted more attention, the market size of the medical diagnostic imaging equipment has reached nearly 50% of the entire medical device markets.
[0006] As every kind of diagnostic imaging equipment has been accomplishing faster diagnosing time, real-time diagnosis and multi-dimensional imaging (e.g., 3D imaging and 4D imaging), various diagnostic methods have been developed for application in the medical diagnostic imaging equipment. However, not only does it take a great length of time to perform diagnosis using the medical diagnostic imaging equipment (e.g., 12 hours for full-body CT, 24 hours for full-body MRI, and 1 hour for full-body PET), but the examination cost is too high for the general public to afford, restraining a wide use of the medical diagnostic imaging equipment.
[0007] A cause of the above problems is the scintillator, which is an essential element that emits light by being in contact with high energy particles during an examination, and of which a crystal scintillator is commonly used. The crystal scintillator, which is expensive and processing of which is difficult and costly, is a main cause of raising the price of medical diagnostic imaging equipment and increasing the examination time due to its difficulty of constituting in a wide area.
SUMMARY
[0008] To overcome the limitations of structural improvement for enhancement of detection efficiency due to processing difficulty and high material costs caused by using the conventional scintillator, the present invention provides a plastic scintillator and a scintillation detector and medical diagnostic equipment using the plastic scintillator that can shorten the examination time and lower the manufacturing cost dramatically by utilizing a scintillator having a same effect and using a more economical material.
[0009] To achieve the above object, the present invention can use a plastic scintillator to maximally reduce a gap between scintillators by allowing the scintillators to have various cross-sectional shapes, constitute the scintillator by including optical fiber, which is an effective detecting material, to enhance detectability, and dramatically increase an area where the scintillator is constituted when utilized in a medical diagnostic imaging equipment.
[0010] With the present invention, the cost of raw material becomes remarkably lower than the conventional scintillator, and it becomes much easier for processing, thereby allowing for more efficient configuration and processing for detection of a high energy particle. Ultimately, the detection area of the medical diagnostic imaging equipment can be dramatically larger to reduce the detection time, allowing for increased convenience for users and supply at lower costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows conventional medical diagnostic imaging equipment.
[0012] FIG. 2 is a perspective view illustrating an embodiment of the present invention.
[0013] FIG. 3 is a perspective view illustrating some embodiments of the present invention.
[0014] FIG. 4 is a cross-sectional view illustrating an embodiment of the present invention.
[0015] FIG. 5 is an exploded view illustrating an embodiment of the present invention.
[0016] FIG. 6 is a perspective view illustrating some embodiments of the present invention.
[0017] FIG. 7 shows a configuration of an embodiment of the present invention.
[0018] FIG. 8 is a cross-sectional view illustrating an embodiment of the present invention.
DETAILED DESCRIPTION
[0019] Hereinafter, some embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0020] Several kinds of medical diagnostic imaging equipment have been developed, for example, positron emission tomography (PET), single photon emission computed tomography (SPECT), computed tomography (CT), magnetic resonance imaging (MRI) and the like. These kids of medical diagnostic imaging equipment detects a high energy particle generated at a particular region with a scintillator (a crystal exhibiting scintillation when struck by a particle), amplifies the high energy particle through a photomultiplier, converts the high energy particle into, and images a photocurrent detection signal to display the particular region where a problem occurs. As described above in the background art, most of these kinds of medical diagnostic imaging equipment are very expensive and thus are hardly utilized in a popular fashion. One of the causes of this shortcoming is the costly scintillator.
[0021] In the conventional medical diagnostic imaging equipment, a photomultiplier 100 has a scintillator (S) inserted therein. As illustrated in FIG. 1 , a plurality of the scintillators (S) are inserted into the photomultiplier 100 to form a scintillation detector 200 , which is arranged on a main body of the medical diagnostic imaging equipment to surround a cross-section of an examined object.
[0022] Used for the scintillator arranged in the scintillation detector is a crystal, but a highly pure crystal (BGO and various kinds of crystal) requires a long time of growth and is difficult to manufacture, making it costly to process and utilize the crystal for the scintillator of a medical diagnostic imaging equipment.
[0023] In the present invention, the conventional crystal (such as BGO) is not utilized as the scintillator of the medical diagnostic imaging equipment, but as illustrated in FIG. 2 , a plastic scintillator 10 and optical fiber 20 constituted therein are provided to have the same effectiveness as the conventional crystal but with a significant economical effect.
[0024] By using the plastic scintillator 10 for the scintillator constituted in the scintillation detector, the performance and detecting effect of the scintillator in accordance with the present invention is unchanged from the conventional crystal scintillator, but is so easy to process that it can be fabricated in various shapes at incomparably low costs.
[0025] It is so difficult and costly to process the conventional crystal scintillator that the scintillator is formed in the shape of a hexahedral cylinder, in which a cross-section on a side of detecting the high energy particle is close to a square, and bound with the photomultiplier. However, as illustrated in FIG. 3 , with the plastic scintillator in accordance with an embodiment of the present invention, it is possible to form a cross-section on a side of detecting the high energy particle in the shapes of various polygons, such as a triangle, a rectangle, a pentagon, a hexagon, a heptagon, an octagon, etc.
[0026] In the present invention, the effectiveness of detection can be enhanced by minimizing a gap among the scintillators, as the scintillation detector 200 is constituted with the photomultiplier 100 in which the plastic scintillator 10 in the shape of a hexagon is used. That is, as illustrated in FIG. 4 , in the case that the scintillation detector 200 of medical diagnostic imaging equipment is constituted with the plastic scintillator 10 having a hexagonal cross-section, which is commonly referred to as a honeycomb structure, gaps that can occur among the scintillators 10 are relatively smaller than those of other cross-sectional shapes, making it possible to detect the high energy particles more efficiently.
[0027] As illustrated in FIGS. 2 , 5 , 6 and 7 , it is possible to process and constitute this kind of plastic scintillator 10 in a highly efficient form and thus to form a hollow section h. Although it is possible to bind the plastic scintillator 10 as is with the photomultiplier 100 , an integrated plastic scintillator 10 ′ can be constituted by forming a hollow section h inside a central part thereof and inserting the optical fiber 20 into the hollow section h in order to collect the light emitted from the plastic scintillator and transfer the light to the photomultiplier. 100 . In such a configuration, it is possible to allow the optical fiber 20 to penetrate through the plastic scintillator 10 or allow the optical fiber 20 to penetrate the scintillator 10 where the scintillator 10 makes contact with the photomultiplier 100 and penetrate the scintillator 10 or be formed not to be exposed to an outside on the side of detecting the high energy particle. Moreover, it is possible to form a plurality of hollow sections h and insert a plurality of optical fiber 20 accordingly, or use a fiber optic core selectively or clad an external part of the core (not shown).
[0028] In constituting the scintillation detector 200 applied with the plastic scintillator 10 in which the optical fiber 20 is formed, one side of the optical fiber 20 can be directly connected with the photomultiplier 100 in order to enhance the effect of detection. It shall be appreciated that, in the case of a plastic scintillator 10 that does not include optical fiber 20 , its cross-section can be bound to the photomultiplier 100 in a conventional way.
[0029] As illustrated in FIG. 8 , the light can be better collected by forming a reflecting film on an external surface of the plastic scintillator 10 , in which case the reflecting film 30 can have a lower refractive index than a conventional plastic scintillator 10 .
[0030] Although there can be various methods of forming a plastic scintillator, in an embodiment of the present invention, fluorescent additives, which can be classified into a primary fluorescent additive and a secondary fluorescent additive, can be used for the plastic scintillator 10 . Used as the primary fluorescent additive can be p-terphenyl (PT) or 2,5-dephenyloxazole (PPO). Used as the secondary fluorescent additive, i.e., a wavelength transfer agent, can be POPOP or 4-bis(2-Methylstyryl)benzene (bis-MSB).
[0031] Used as the fluorescent additive for the optical fiber can be K27, BBQ(7H-benzimidazo[2,1-a]benz[de]isoquinoline-7-one) of National Diagnostics, or Lumogen of BASF. Accordingly, the fluorescent additive in the color of red, orange, yellow, green, blue, purple or pink can be added according to the usage of detection to use an entire wavelength between 200 nm and 900 nm, thereby allowing for use in the conventional photomultiplier tube (PMT), silicon photomultiplier (SIPM) or multi pixel photon counter (MPPC).
[0032] Used for a material to clad the optical fiber can be poly methyl metha acrylate (PMMA), of which the refractive index is 1.59 and the density is 1.19, in the case that PS is used as a core of the optical fiber for primary cladding of the optical fiber. In addition, any material (e.g., PTFE or PEFE) having the refractive index that is smaller than that of PMMA can be used for secondary cladding over the primary cladding, or the secondary cladding can be optionally omitted.
[0033] In the case that PMMA is used for the core of the optical fiber, it is preferable that PTFE or PEFE, of which the refractive index is smaller than that of PMMA, is used for the cladding. That is, it is preferable that aluminum or titanium dioxide (TiO 2 ) is used for the reflecting film located outside a scintillating cell,
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The present invention relates to a scintillation detector, which is largely divided into a scintillator and a photomultiplier, as a constituent element of a medical diagnostic imaging equipment, a scintillator, and a medical diagnostic imaging equipment using the same, and more specifically, to a plastic scintillator, and a scintillation detector and a medical diagnostic imaging equipment using the same wherein a plastic scintillator is provided as a scintillator constituting a scintillation detector of a medical diagnostic imaging equipment instead of a known crystal scintillator, thereby allowing easy processing of a scintillator, improving detection due to various configurations and remarkably reducing processing costs.
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FIELD OF THE INVENTION
The present invention relates to a valve assembly comprising a first valve component in fluid connection with a first duct, a second valve component in fluid connection with a second duct, each component having a housing and a closure member, the first closure member having a pivot axis, extending transversely to the first duct, the first closure member being pivotable around the pivot axis between a closed position in which the closure member extends transversely to a longitudinal centre line of the first duct and an open position. The invention is particularly suitable for use in hydrocarbon transfer systems as an emergency release valve, for instance for LNG transfer. The invention is particularly applicable in the event of the breakage of a pipe or in any emergency situation requiring two pipe segments to be disconnected.
BACKGROUND OF THE INVENTION
Connection arrangements of this type are well known for interconnecting pipelines for supplying and receiving fluid between two stations, one of which could be a fixed station such as an offshore mooring point and the other of which could be a mobile station, such as a hydrocarbon tanker. Known connection and disconnection arrangements are provided with an emergency disconnection device making it possible, in an extreme situation of drift or accident—for example in case of fire—to distance the mobile pipe section from the fixed pipe section in order to prevent damage to the structure or wrenching off of the pipes, while ensuring containment of the fluid in the pipelines.
In the known arrangements, the pivot axes of the valve disks of the two interconnected pipe sections are spaced apart from one another in the axial direction of the pipe sections. When these disks assume their closed positions they delimit between them a relatively large space that is filled with fluid. In the event of emergency disconnection, this quantity of fluid is lost to the environment. Such an incident may cause pollution of the environment or involve a risk of fire. This is the case in particular for the transfer of liquefied natural gas (LNG) between, for example, a loading or unloading terminal and a liquefied gas tanker.
In the past, many different types of valves have been used in various environments and applications to control the flow of fluids through a pipeline, conduit, or the like. Linear valve types include valves such as globe valves, gate valves and diaphragms, whereas quarter turn valve types include butterfly valves, ball valves and plug valves. These valves can be manually operated or can be actuated and modulating, depending on the specific application. Gate valves, plug valves, wedge valves and ball valves, for example, have all found their respective niches in the art of fluid flow control. It is of primary importance for such valves to provide for substantially leak-free operation; it is especially so for valves regulating the flow of high pressure fluids or potentially hazardous fluids such as highly flammable or caustic substances. Ease of operation, that is, opening and closing, is sometimes as important a feature of a valve, particularly a high pressure valve, as leak-free operation. If a valve cannot be operated quickly and with relatively little effort, besides the wear and tear on the valve parts, the excess time and effort spent in operating the valve and the related inconvenience associated with such a high torque valve can lead to other adverse consequences. Thus it is clearly desirable and advantageous to employ valves that are both reliable, that is, leak proof, and fast and easy to operate, preferably requiring very low torque attainable with only hand or light tool application.
An example of an arrangement for connecting and disconnecting two pipe sections of a fluid transfer system is found in U.S. Pat. No. 6,877,527 where each section includes a butterfly valve with a disk pivotally mounted inside, rotating about a swivel axis between a closed position closing the cross-section of the fluid flow and an open position opening the cross-section of the fluid flow. The swivel axes extend perpendicular to the pipe axis and parallel to each other. This configuration involves for each valve an actuating mechanism and is relatively complex and heavy. Although the known construction reduces the amount of fluid trapped when connection of the pipe sections occurs, it fails to prevent any fluid from staying trapped once the connection is realized.
An example of a cam actuated split ball valve is found in U.S. Pat. No. 5,265,845 where the split ball halves are pivotably mounted to the head member to be pivotable about the mounting means alternately to separate the halves from one another or to collapse them toward one another. The closure member is rotatable with the stem and head member alternately to place the flow port portions in register with the seats to open the valve, or to align the sealing surfaces with the seats to close the valve. An actuating cam is disposed in the valve body between the split ball halves for alternately forcing them apart or permitting them to collapse toward one another and away from sealing engagement with the seats. This arrangement retains its ease of operation and low operating torque at very high working pressures but it does not permit any disconnection of the pipe sections that are attached to the valve.
Another connecting device for conduits is described in U.S. Pat. No. 4,335,747, disclosing in each conduit a spherical valve element having a diametrically extending through-hole. In one pipe section, the mating surface of the housing in which the spherical element is seated is formed with an opening through which a part of the valve element projects. On the other conduit, the spherical valve element does not project beyond the mating surface of the housing but is formed with a part-spherical recess for receiving the projected portion of the valve element in the first ball valve assembly. In this way inclusion of air can be prevented upon interconnecting the two pipe sections, which is especially advantageous in cryogenic applications. Each ball valve however is driven by individual actuating members, making the construction relatively complex and heavy.
An emergency shut-off device is described U.S. Pat. No. 5,305,776, wherein two valves each have an obturator pivotable in the pipe body around parallel pivot axes, so that it can assume a shut-off position transversely to the length direction of the pipe and an open position substantially perpendicular to its shut-off position. Each obturator has an engagement device for engaging the obturator of the other valve fixing the two obturators in a contiguous arrangement in their open positions, which they assume normally, and releasing the obturators so that they can assume their shut-off configurations when the valves move apart because the joint has been subjected to loads equal to or greater than the breaking load. This arrangement has to be changed after each emergency shut-off as the means joining the two obturators have to be broken to separate the obturators.
It is an object of the present invention to overcome the problems discussed above. It is in particular an object of the invention to provide a valve assembly which can be connected and disconnected repeatedly while avoiding leakage. It is in particular an object of the invention to provide a valve assembly which is of a simple and light-weight construction and which is easy to operate.
SUMMARY OF THE INVENTION
Thereto, in a valve assembly according to the invention, the first and second closure members are provided with coupling means for releasably interconnecting the closure members, such that the second closure member can be moved together with the first closure member upon pivoting of the first closure member around the pivot axis, the second closure member comprising connector means for engaging with complementary connector means on the second housing in a closed position of the second closure member, which connector means maintain the second closure member in a non-pivotable sealed attachment with the second housing upon detaching of the coupling means and separating the valve components.
By providing the first closure member, which may be any type of valve such as for instance a butterfly valve, a ball valve, or a cylindrical valve, with a pivot axis, the first closure member can be rotated into an open or closed position. As the second closure member is mechanically linked to the first closure member via the coupling means while the connector means of the second closure member are disengaged from the second housing, the second closure member is pivoted in conjunction with the first closure member between an open and closed position. In case of separation of the pipe sections, both closing members are pivoted in conjunction to assume their closed position whereafter the coupling means are released while the connector means of the second closure member engage with the second housing. As during separation the pivoting function of the second closure member is not required, it is possible to sealingly clamp this member to the second housing in a non-pivoting fluid tight manner.
As a single drive member only needs to be provided on the housing part of the first closure member, the valve according to the invention can be of a simple, easy to operate and light-weight construction. Hence the valve assembly according to the invention is particularly suitable for use on a hydrocarbon transfer arm. Furthermore, mechanical coupling of the first and second closure members in their operational state ensures that a minimum of liquid is included between the first and second closure members, such that on separation of the valve components, spillage of liquid is prevented.
For quick release, the first and second housing may comprise external fixing devices for interconnecting the first and second housing in a fluid-tight manner. The external fixing devices may comprise a number of radial projections on each housing, and a corresponding clamping device hingedly attached to the projection of one housing and clampingly engageable with an opposite radial projection upon hinging.
In one embodiment, the first closure member comprises a body having a through bore, an entry surface and exit surface delimiting the through bore and a coupling surface extending substantially transversely to the entry and exit surfaces, the coupling means being situated on or near the coupling surface, at which coupling surface the closure members are contiguous, the body being connected to a drive shaft extending through the housing to an exterior drive position for pivoting the body around the pivot axis. In this way, a solid valve body, such as a cylindrical or spherical valve body, can be used that is able to withstand high pressures and which is firmly supported within the housing.
A draining channel may extend from the port, through housing part, to the outside, in line with the shaft and can optionally comprise a relieve pressure valve. Via the draining channel, fluids may be transported back into the first duct section via a closed loop, to minimise fluid spillage.
The first and second housings may define a spherical seating, the first and second closure members defining a ball valve, the connector means of the second closure member comprising at least one notch or projection extending transversely to a spherical sealing surface, the connector means on the second housing comprising a complementary projection or notch extending transversely to a spherical sealing surface. The split ball valve provides a low torque open and close function while in a separated state, the spherical section of the second pipe segment can maintain the second pipe segment in a properly closed position.
The spherical segment of the second closure member may be mechanically attached to the second housing via projections on each side of the longitudinal centre line, the closure member on the housing comprising on each side of the longitudinal centre line a groove, the notch being accommodated in the groove upon pivoting the second closure member around the pivot axis into the closed position.
Instead of via rotation around the pivot axis, the spherical segment of the second closure member may be attached to the second housing by pivoting of the pivot axis around the length direction when the second closure member is in its closed state.
In one embodiment, the first and second housing comprise a housing sealing member on a housing surface, the first and second closure members comprising a coupling sealing member on the coupling surface and the second and first housing and/or the closure members comprising a closure sealing member for engaging with a corresponding sealing surface of the first and second closure members and/or the housings. In this way, the housing parts and the closure members form a sealed containment space and fluid transfer to the space between the closure members and the housing is prevented.
In a further embodiment, the combined first and second housing and the first and second closure members are substantially cylindrical, the coupling means on the housing comprising on each side of a longitudinal centre line an annular groove with a midpoint on the pivot axis, the closure members comprising a flange extending transversely to the longitudinal direction into the annular groove. In this way a cylindrical valve of simple construction and easy, low torque operation is obtained.
In again another embodiment, the closure members is substantially plate-shaped, the second housing comprising a internal notch or groove extending in a direction transversely to the fluid flow direction, the second closure member comprising a complementary groove or flange extending transversely to the fluid flow direction into the annular groove for engaging in its closed position with the internal rim.
BRIEF DESCRIPTION OF THE DRAWINGS
A number of embodiments of a valve assembly according to the present invention will by way of non-limiting example be described in detail with reference to the drawings. In the drawings:
FIG. 1 shows a cross sectional view of a split ball valve according to the invention in an open state,
FIG. 2 shows a cross sectional of the valve of FIG. 1 in a closed state,
FIG. 3 shows a cross sectional view of the valve of FIG. 1 wherein the valve components are separated,
FIG. 4 shows a sectional top view along the line IV-IV of FIG. 3
FIG. 5 a shows front view of the second housing and second closure member of the split ball valve of FIG. 3 ,
FIG. 5 b shows a cross sectional view along the line Vb-Vb in FIG. 5 a
FIG. 5 c is a detailed view of a locking mechanism between the second closure member and the housing of FIG. 5 b,
FIG. 6 a shows a cross sectional view of another embodiment of a split ball valve according to the invention with the valve components in a separated state,
FIG. 6 b is a detailed view of a locking mechanism between the second closure member and its corresponding housing part
FIG. 7 a shows a front view of the second housing and associated closure member of the split ball valve of FIG. 6 a
FIG. 7 b shows a cross sectional view along the line VIIb-VIIb of FIG. 7 a
FIG. 8 shows a top view of a cylindrical valve according to the invention in a closed state (solid lines) and in an open state (dashed line),
FIG. 9 shows a cross sectional view of the split cylindrical valve of FIG. 8 with the two housing parts in a separated state,
FIG. 10 a and 10 b shows a cross sectional view of a split gate valve according to the invention in an open and a closed state, respectively, and
FIG. 10 c shows a cross sectional view of the split gate valve of FIG. 10 a and FIG. 10 b with the two valve components in a separated state.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a valve assembly 1 in the form of a split ball valve with a first valve component 2 and a second valve component 3 . The valve assembly 1 has a valve gate 8 with a body 10 which can pivot around pivot axis 9 . Each valve component 2 , 3 is connected to a respective pipe segment 5 , 7 . The valve gate 8 is in the form of an oversized ball so that the port 11 in the ball is of the same cross-sectional size as the flow paths 13 , 14 of pipe segments 5 , 7 which significantly reduces the friction losses. A single drive stem 15 , having a grip 14 is attached to the body 10 and extends along the pivot axis 9 through first housing part 17 . The grip 14 serves for operation of the valve. This operation can be a manual operation, or an automated operation via a rotary actuator. A second housing part 18 is connected to the first housing part via 17 via an external fixing device having radial projections 20 , 21 , 22 , 23 on each housing part 17 , 18 . The respective pairs of projections 20 , 21 and 22 , 23 are clamped together via hinging clamps 24 , 25 . The sealing surface of the valve gate 8 slides along the spherical surface of the housing parts 17 , 18 , while seals 27 , 28 and 31 , 32 prevent fluid from entering between the valve gate 8 and the housing parts 17 , 18 . The seals 29 , 30 on the interface between the detachable housing parts 17 , 18 prevent leakage of fluids from the valve housing.
In FIG. 1 the split ball valve is open as the port 11 is in line with the fluid flow paths 13 , 14 , and the fluid is allowed to pass from pipe segment 5 , via an entry surface 33 of the gate 8 and an exit surface 34 , into the pipe segment 7 . The housing part 18 is provided with slots (recesses) 36 , 37 for receiving radially projecting connector means 38 , 39 provided on a detachable gate part 41 for locking this gate part to the second housing part 18 .
The ball valve 8 that is shown in FIG. 1 can also be provided with a leak path 42 having a purge port in housing part 17 to the outside, optionally a relieve pressure valve can be added. A closed loop links the leak path to the inside of the flow path 13 to avoid spillage of the fluid purged.
FIG. 2 shows the valve assembly of FIG. 1 in the closed state. In this configuration, the stem 15 has been rotated by a quarter turn around the axis 9 such that the port 11 now is perpendicular to the direction of fluid flow through the pipe segments 5 , 7 . The connector means in the form of the projections 38 , 39 on the gate part 41 that mate with the slots 36 , 37 in the second housing part 18 . The slots 36 , 37 can be shaped as a part of an annular groove with its center on the pivot axis 9 , such that the groove can receive the projections 38 , 39 while rotating the valve gate parts 40 , 41 jointly around the pivot axis 9 . The two valve parts 40 , 41 are interconnected via coupling means on respective coupling surfaces 12 , 16 of the gate parts 40 , 41 in the form of a protrusion 45 on gate part 40 and a mating recess 46 in gate part 41 . The coupling means ensure a mechanical connection between the valve gate parts 40 , 41 such that upon rotation of the gate part 40 around pivot axis 9 , the gate part 41 is entrained. The coupling means may alternatively comprise magnetic coupling means, friction material or any other coupling means ensuring rotational coupling whilst allowing separation of the gate parts 40 , 41 in the length direction L of the pipe segments 5 , 7 . The spring loaded seals 27 , 28 and 31 , 32 between valve gate 8 and the housing parts 17 , 18 and the static seals 29 , 30 on the housing interface ensure a sealing of flow paths 13 , 14 of the two valve gate parts 40 , 41 once in an interconnected position.
The coupling surfaces 12 , 16 of the gate parts 40 , 41 can also divide the port 11 into two parts 9 (not shown). In that case the coupling surfaces 12 , 16 will not be contiguous on all their surface.
FIG. 3 shows the valve assembly 1 after the housing parts 17 , 18 and the valve gate parts 40 , 41 have been separated in the length direction L. The hinging clamps 24 , 25 are pivoted to disengage from the radial projections 20 , 22 on the housing part 17 . The valve gate part 40 is disengaged from the valve gate part 41 as the protrusion 45 is removed from the recess 46 . The gate part 41 is locked to the housing part 18 via the projections 38 , 39 engaging with the slots 36 37 in the housing part 18 . The flow paths 13 , 14 in pipe segments 5 and 7 are closed by the respective gate parts 40 , 41 .
FIG. 4 shows a sectional view of the valve configuration of FIG. 3 through the line IV-IV. The extremity of the leak path 42 is visible and it appears clearly that it enables the fluid trapped in the gate port 11 to be removed once the gate is closed. The seals 51 , 52 on the coupling surface 12 of the gate part 40 prevent any leakage of the fluid once the coupling surface 12 is contiguous with the coupling surface 16 of the gate part 41 .
FIG. 5 a shows a front view of the second closure member 41 and the surrounding housing part 18 once the ball valve has been split. In this configuration the clamping means 24 are evenly distributed around the exterior of the housing part 18 . The connector means in this case comprise for example pins or rims 38 , 39 that are seated in grooves 36 , 37 in the housing part 18 to sealingly lock the closure member 41 to the housing 18 of pipe segment 7 . The pins or rims 38 , 39 enter the grooves (or recesses) 36 , 37 via an opening 55 , 56 and travel to their end position by rotating the valve gate 8 by a quarter turn around the pivot axis 9 from the open flow position shown in FIG. 1 to a closed position shown in FIG. 2 . In this way, the pipe segment 7 is sealingly closed. The coupling means on the closure member 41 comprises the recess 46 . It attaches the second gate part 41 rotationally to the gate part 40 and is shown here to be situated in the centre of the second closure member 41 .
An alternative to the clamping means can be to have the two body parts 17 , 18 as well as 10 , 41 rotatable with respect to one another around the longitudinal centre line ( 26 ) using bearing means to unlock the two parts from each other (not shown).
FIG. 5 c shows an enlarged detail of the seal 32 , which is spring biased by a spring 57 seated in a cavity in the housing part 18 , against the closure member 41 for preventing fluid from leaking between gate part 41 and the housing part 18 . As can be seen from FIG. 5 c , at the end position of the grooves 36 , 37 the there may be an additional locking mechanism 58 , 59 , such as a spring biased ball, engaging with the top of the protrusions 38 39 to lock the closure member 41 to the housing part 18 when it reaches it sealing end position.
FIG. 6 a shows a cross-sectional view of another embodiment of the connector means, which comprise radial projections or a rims 60 , 61 attached to the inner perimeter of the second housing part 18 . In the enlarged detail of FIG. 6 b it is clearly shown that the gate part 41 is provided with a shoulder 62 , 63 which engages with the projections or rim 60 , 61 on the housing when the closure member is in its closed end position. It is clear in this embodiment that the projections or rims 60 , 61 are integral with the housing part 18 . The position of the projections or rims 60 , 61 in the interior of the housing part 18 and the shoulders 62 , 63 are shaped in such a way that the projections 60 , 61 receive and guide the shoulders 62 , 63 on the gate part 41 while rotating the valve gate around pivot axis 9 upon closing the gate.
FIG. 7 a shows a front view of the second gate part 41 which is sealingly locked in the housing part 18 . The projections 60 , 61 at the interior of the housing part 18 define grooves 65 , 66 indicated with the dashed lines. The projections 60 , 61 define openings 67 , 68 between each projection and the interior wall of the housing part 18 , through which openings the shoulders 62 , 63 of the second gate part 41 can enter into the grooves 65 , 66 upon rotation of the second gate part 41 around the pivot axis 9 into its sealingly closed position.
FIG. 8 shows a top view of a cylindrical valve assembly according to the invention in the closed state. The dashed lines indicate the open, or flow-through position.
FIG. 9 is a cross sectional through the line IX-IX in FIG. 8 wherein the gate part 40 seal off pipe segment 5 and the gate part 41 closes off pipe segment 7 . The valve gate 8 comprises a top flange 70 and a bottom flange 71 which are guided in annular recesses 70 ′, 71 ′ in the interior surface of the housing parts 17 , 18 and which form the connector means sealingly locking the parts 40 , 41 of the valve gate 8 to the respective housings 17 , 18 . Seals 73 , 72 are situated between the housing part 17 and the gate part 40 . Seals 74 , 75 ensure that in the interconnected state of the housing parts 17 , 18 , no leakage of fluid can occur to outside the housing. Seals 76 , 77 prevent fluid ingress between the valve gate parts 40 , 41 after interconnection of the coupling surfaces 12 , 16 , and seals 78 , 79 ensure liquid-tight sealing of the pipe segment 7 by the gate part 41 upon separation of the valve components 2 , 3 .
FIGS. 10 a to 10 c show another embodiment of a valve assembly of the present invention in which the valve is a butterfly valve and the valve gate 8 is disk-shaped. The closure members 40 , 41 making up the valve gate are connected to the valve stem 15 which extends from a top seat 89 in the pipe segment 5 to a diametrically opposed lower seat 90 . The housing part 17 at the end of pipe segment 5 comprises the seats 89 , 90 in which the valve stem 15 is supported. The housing 18 at the end of the pipe segment 7 comprises the connector means 93 , 94 which may be in the form of a groove receiving a shoulder 95 , 96 on the disk shaped gate part 41 . Seals 80 , 81 mutually seal the housing parts 17 , 18 when they are contiguous, seals 82 , 83 seal the first gate part 40 against the inner wall of the housing part 17 , seals 84 , 85 seal the interface along connection surfaces 12 , 16 of the first and second gate parts 40 , 41 when they are contiguous and seals 86 , 87 seal the second gate part 41 against the inner wall of the housing part 18 when in the closed position.
The invention is not limited to the embodiments shown in figures. Hence, a case where the ducts 5 and/or 7 would be inclined in relation with the axis 26 is also covered by the present invention.
The valve assembly components can be made, for example, of any metallic, plastic or elastomeric components.
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Valve assembly including a first and second valve components in fluid connection with respective first and second ducts, each valve component having a housing and a closure member, a first closure member having a pivot axis extending transversely to the first duct, the first closure member being pivotable between closed and open positions. The first and second closure members each have a coupling element releasably interconnecting the closure members, so the second closure member can be moved with the first closure member upon pivoting of the first closure member around the pivot axis, the second closure member including connector element for engaging with a complementary connector element on the second housing in a closed position of the second closure member, which connector element maintains the second closure member in a non-pivotable sealed attachment with the second housing when the valve components are separated.
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RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 11/326,821, filed Jan. 6, 2006 now U.S. Pat. No. 7,751,051, which is based upon and claims the benefit of priority from prior U.S. provisional application Ser. No. 60/641,906 filed on Jan. 6, 2005. The entire contents of these applications are incorporated herein by reference in their entirety.
TECHNICAL FIELD
Video is typically recorded by time, for example, 30 frames per second. By recording frames according to distance traveled, a new database is created. This video or sequential image database incorporates geographically referenced images that are spatially related rather than time related. By the selection of a distance between frames to identify which frames are to be acquired, a dramatically smaller database results that is able to be searched more easily. This provides for a dramatically reduced size in the database and is a technique of data compression. Specific frames or data can be more easily retrieved by geographic position that can be determined by Global Position Satellites, Inertial systems or other electro mechanical sensors. Traditionally, forward looking video views have not been recorded by distance traveled or geographic position. The present invention involves a cognitive change detection system having particular utility for military or detection of a changed circumstance. This circumstance may represent a hazard to a vehicle traveling upon the roadway, such as a change in the roadway, cracks in pavements, tunnels or bridges or roadside encroachments. In addition, changes in nearby objects such as power lines, building facades, parked cars can be identified. The hazard could consist, for example, of a munition which has been placed on the shoulder of a roadway and which is capable of being detonated when a vehicle is within range of being impacted by detonation of the munition. By practicing the present invention, recognition of a changed circumstance such as the placement of a munition as compared to a previously memorialized record (database) of the roadway and surrounding landscape can effectively be used to recognize a hazard enabling the vehicle operator to circumnavigate or render harmless the hazard if necessary. Other applications include nighttime driving to provide a daytime image of the current position and heading, a more precise navigation to conform to a previously identified path and the enhancement of current imagery with previously acquired data or imagery.
It is also possible to use the invention to identify a current GPS position by selecting the closest matching frame in the database with a known GPS co-ordinate that was previously acquired.
BACKGROUND OF THE INVENTION
Often times, for example, military vehicles are called upon to travel routes which are well known to hostile forces. As a consequence, munitions such as bombs and mines can be surreptitiously placed along such a route for detonation at a critical time when such vehicles are proximate to such hazards. Unless a trained observer was so familiar with a particular route that any change in the topography such as the placement of a bomb or mine would readily come to the attention of such a vehicle operator, it is difficult if not virtually impossible to foresee the hazard and thus avoid its consequences.
In the past, topography including roadways have been geomapped, principally by aircraft traveling above the to be mapped region from top down views. However, in light of wobbling aerial camera platforms, look angle limitations and lens distortions converting an aerial map of a region to a surface based operator view, prior geomapping techniques have proven complex. Additional complications come from the mosaicing techniques that are required to integrate frames along the route being traveled into a searchable database. Further, for a vehicle operator to identify changes between geomapped imagery, it has been determined to be cognitively most helpful to provide a split screen or some other type of parallel tracking display of a geomapped route to the route currently being navigated to enable rapid comparisons to be made between current conditions and those which act as a standard upon which future actions or detections would be based.
The hardware requires the simultaneous or near simultaneous display of the current image and the geographically referenced database image.
It is thus an object of the present invention to provide a ready means of providing a vehicle operator sufficient information to enable the operator to avoid a natural or manmade hazard or identify a specific changes in nearby objects or their relative positions.
It is yet a further object of the present invention to provide a means of providing baseline data for comparing a current route with a standard baseline view of the same route taken previously for ready, real time comparisons.
It is yet a further object of the present invention to provide means of alerting the driver to roadside hazards by looking forward in the database to what is over a hill or around a bend.
It is yet a further objective of the present invention to integrate information from the inspection of roadways or other roadside conditions in a format which highlights such conditions and hazards and which presents them to a vehicle operator in a timely fashion to provide the operator the opportunity to take effective remedial action.
It is a further object to provide daytime views given a GPS location and heading.
It is a further object to present to a driver a behind the vehicle view based on previous views with the vehicle perimeter represented on screen so that the current relationship of the wheels to hazards can be viewed and is approximately accurate to the current vehicle position.
It is a further object to provide a means to reduce the number of frames and size of a database by recording imagery by distance separation rather than time. This was usually done by recording all frames in a sequence done at 30 frames per second and tagging the GPS position on all thirty frames. Although the invention can be practiced with all 30 frames, the preferred embodiment is to record a frame after the camera has moved a specified distance to reduce the bandwidth and storage capacity required.
It is further object to utilize other forms of imagery or data such as ladar, radar, sonar, magnetics, multi-spectral, audio, computer renderings from depth maps or wireframes or other forms of data such as sound that can be discretely acquired by geoposition. These alternative sources of data can be mixed such as thermal with daytime video, magnetics with video, multi-spectral with rendered imagery.
It is a further object to identify a current GPS position by selecting the closest matching frame in the database with a known GPS co-ordinate that was previously acquired.
These and further objects will be readily apparent when considering the following disclosure.
SUMMARY OF THE INVENTION
The present invention involves a method of detecting a changed condition within a geographic space from a moving vehicle. The method comprises capturing and memorializing images of the geographic space in conjunction with GPS/geographic coordinates associated with said geographical space. The geographical space is traversed from said moving vehicle while accessing GPS or other geographic coordinates. The memorialized images are accessed and played back by coordinating geographic coordinate data on said memorialized images with the traversing of said geographic space such that said memorialized images being viewed are of the same geographical space being traversed (i.e. the position of the camera now and in the past are within the same geographic coordinates and headings +/− some tolerance). Both memorialized images and the images of the traversed geographic space are presented to an observer enabling the observer to make a direct comparison of the memorialized images and images of the geographic space being traversed to the observer. Ideally, the memorialized images are created by employing a video camera which can also be used to present the geographic space being traversed. Alternatively, other image capturing devices can be employed such as infrared cameras, sonar, or sensor data such as magnetic or sound data that can be graphically represented on a screen. To present the most direct comparison, the camera presenting the traversed images from the moving vehicle should be placed in approximately the same location and heading as that of the camera employed to capture the memorialized images with a similar field of view. Fields of view can be better matched optically or by electronic scaling. Image stabilization techniques can also be used to improve the relative registration between images. Both images can be presented upon a screen, such as a split screen in which the traversed images are presented above and the memorialized images are presented below. Alternative displays such as sequential presentations, alternating, super-imposition or keying and matting techniques can also be used. By GPS coordination, the images of the same geography are presented to an observer simultaneously enabling the observer to quickly and intuitively recognize any changed conditions in the roadway. Further, although the memorialized images and traversed images can be taken and captured during the daytime to provide a meaningful comparison with daylight views, the present invention can also be employed to enhance night driving by comparing memorialized images taken during the day when visibility is relatively good and playing back those images on a suitable split screen with real time images taken at night or during inclement weather. The display of the recorded daylight single view selected by current GPS position presents valuable information that may not be visible in the current situation. The simultaneous display of the current and previous condition would not be required. Sometimes in inclement weather or GPS obstruction, the current GPS could be lost. By comparison of current imagery to the database imagery, a current GPS position could be selected by the closest image match to a specific frame in the database.
Because a driver may not have a direct view of his wheels in relationship to a ravine or cliff or other hazard, an accidental roll over can occur. By using a GPS based offset that is some distance behind a vehicle, a navigation view can be presented to a driver. The outline perimeter of the vehicle including its wheels can be superimposed over the collected imagery. A view can be displayed that includes a view of the road and vehicle that appears to be from a camera behind the vehicle. This is accomplished by using a GPS position that is approximately 20 feet from the current position to determine the video frame best associated with the current position.
By placing a dot (Breadcrumb) in the proper location on a Cartesian coordinate system on the display one can create a map that represents the memorialized data. Breadcrumb marks on a top down map for each frame can then be composited to provide accurate maps of the driven area. These maps may be overlayed onto standard reference maps which may be imported into the system. This provides a graphic interface that can be used to present the view of the route that at any specific speed selected.
Change detection is enhanced at night by the use of auxiliary lighting in the visible or infrared wavebands. At night, using auxiliary lighting placed lower than the camera, exaggerated elongated shadows produce an enhanced shadow effect to highlight changes. This auxiliary lighting can be constant or pulsed to co-ordinate with the GPS capture of the frame after a specific distance is traveled. The lighting can be in the visible and or non-visible range.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic block diagram of the essential components necessary in carrying out the present invention.
FIG. 2 depicts a typical split screen presentation of data which would be presented to a vehicle operator in practicing the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Others, in the past, have taught methods of recording images and associating them with GPS or geographic coordinate data to provide playback that was position, rather than time dependent. For example, reference is made to U.S. Pat. No. 6,741,790, the disclosure of which is incorporated by reference. The '790 patent teaches a system including hardware and software which are configurable and operable in three modes, namely, recording mode, indexing mode and playback mode. In the recording mode, the hardware employed therein is connected to a GPS receiver and video recording device and permits GPS data to be recorded on the same recording medium that images are recorded on using the video recording device. As a result, a particular geographic location associated with particular images can be directly referenced by GPS data. After recording the images, the hardware device is connected to a computer having the appropriately installed software causing the GPS data to be transferred from the recording medium to the computer as the recorded images are played. During this indexing step, the computer draws a map showing all of the GPS reference locations recorded on the recording medium. Each map location represents a location where images were recorded with GPS data. Once the indexing mode is completed, the system disclosed in the '790 patent can be used to play back the images so recorded, in accordance with the selection of a location on the map. During this step, called the playback mode, a marker may be selected on the computer generated index map and the system will cause the video recording device to play back the images that were recorded at the selected location. The '790 patent also teaches recorded images being transferred to some other media such as a CD ROM or hard disk causing the computer to play back the images that were recorded at that selected location. However, no one to the applicant's knowledge has adapted this technology for the purpose presented herein. This new invention can use the GPS to determine when a picture is recorded to reduce the number of frames in memory and which image to be called during playback. Although all frames can be recorded, it is best to only record those separated at a deliberately set distance. Thus the camera frame rate is dependent on the velocity of the camera. This can also increase the required camera frequency of recorded imagery past 30 frames per second for higher travel velocities through the use of a GPS triggered camera.
In addition, U.S. Pat. No. 6,895,126 teaches a system and method for synthesizing images of a locale to generate a composite image that provides a panoramic view of the locale. The '126 patent discloses employing a video camera moving along a street recording images of objects along the street. The GPS receiver and inertial navigation system provide the position of the camera as the images are being recorded. The images are indexed with the positioned data provided by the GPS receiver and inertial navigation system. According to one aspect of the '126 invention, an image recording device moves along a path recording images of objects along the path. As noted, the GPS receiver and/or inertial navigation system provides position information of the image recording device as the images are being acquired. The image and position information are provided to a computer to associate each image with the position information. As such, it is known in the prior art to associate GPS coordinates with recorded image data for later playback. The disclosure of U.S. Pat. No. 6,895,126 is incorporated herein by reference.
As a first embodiment, the present invention involves a detection system utilizing human intervention to detect changes in a scene by displaying video of a topography such as a roadway along with imagery captured from a previous trip. During acquisition, the system captures images from a live video feed and “meta-tags” them with additional information including the location and orientation of a specific viewpoint. Important “meta tag” information would include, for example, direction of travel and GPS coordinates and/or elevation. These ‘meta tags’ are then associated with specific frames of the previously taken video image. During playback, the system utilizes current location and orientation through GPS data acquisition to recall imagery previously captured from approximately the same location and orientation. Ideally, the two images are displayed on a single screen above and below one another. In some applications, such as driving at night, only the stored view will be displayed. GPS data acquisition provides the coordinates that determine the closest “stored views” to the vehicle's current location. This can also be done using various “closest matching frame” software. This system then selects corresponding views from a database to produce the nearly exact view that a vehicle operator, such as a soldier, is observing in real time in the vehicle. Compensation of the database view can be made for variances in camera field of view, speed, distance to the center of the road and X and Y variances from the position on the road from which the reference data was taken. These corrections can be determined from physical sensors on the camera platform such as inclinometers and accelerometers or from calculations derived from the sequence of images. The information is presented in an enhanced format for easy comparison to the observer to enable a vehicle operator to make real time decisions about a road hazard.
As a preferred embodiment, the image can be deliberately distorted by increasing the horizontal width to minimize the relative vertical motion or an unusual horizontal aspect ratio can be used to provide the viewer with less vertical distance between before and after pictures thus minimizing eye movement This can be done for example by cropping the image reducing the area above the horizon In carrying out this function, reference is made to FIG. 1 showing system 10 as constituting one version of the present invention. Specifically, system 10 includes a computer 11 which is fed information from elements 12 and 13 . Element 12 is an image source generator such as a visual or thermal camera which is employed in conjunction with GPS device 13 to “meta tag” frames generated from camera 12 and applied to computer 11 for storage. The image developed through this established reference would appear in the bottom portion of split screen 14 in image area 16 as discussed further in reference to FIG. 2 . When traveling over the same route upon which the image projected in field 16 is played back, camera 12 again generates an image and the image thus created is coordinated with GPS device 13 and is again introduced to computer 11 which generates a real time image in upper frame 15 of display 14 . Because the stored image and current image are both “meta tagged” with GPS coordinates, playback of a specific scene in conjunction with a current route being undertaken are coordinated for direct comparison.
The utility of the present invention can be appreciated in reference to FIG. 2 . As noted, the split display screen 14 displays roadway 17 and its surrounding topography. The image displayed in lower half 16 of display 14 is an image taken of a roadway at an earlier date and time. Roadway 17 and its surrounding topography displayed in upper screen portion 15 shows a similar portion of the roadway, each view expanded horizontally to enhance visual recognition of horizontally presented objects such as objects 19 sitting on the outside of shoulder 18 . Images generated are ideally taken with a telephoto lens in order to provide adequate time for a vehicle operator to take action in the event that the operator wishing to investigate the nature of new objects 19 in the event they represent munitions or other potential hazards applied to the roadway by hostile forces.
The image generated in row or frame 16 , that is, that showing a previous depiction of a roadway and surrounding topography can be acquired from a multitude of sources such as previous convoy runs, UAV, manned aircraft or robotics. Such information can be electronically submitted to a central server which can be accessed by remote displays.
The main hardware components involved are a laptop PC, server or DVD burning system, small GPS receiver and a video camera, or other sensor providing 2 or more dimensions of data. The principle software components include simultaneous video/data capture and playback, the capturing of location and orientation information from sensors on USB and/or serial ports, utilizing “meta tags” to associate the different data sets, storing the data in a format that can be shared or combined with other geo-spatial information, techniques for annotating the stored imagery to locate features such as potentially dangerous areas along the route, an interface to interact with the data and a way to share the data with others who will travel the same route at a later time.
An advanced functionality under consideration includes the ability to track or predict viewpoint motion in cases of a limited GPS signal.
Other identified significant applications include training and dispatch or route planning. Driving simulators would be improved from the current cartoon like images to real video.
Nighttime operations with IR and thermal sensors and alternative sources such as magnetic maps or ladar can also be utilized.
A simple training device is a DVD of the recorded route that is played on a DVD player.
As to simultaneous video capture and playback, live video will be displayed with previously captured imagery in an over/under fashion on two parts of the screen to facilitate change detection comparison. To create a random accessible database (as opposed to an MPEG video stream) a JPEG storage architecture can be used. The capture of the still images will be based upon parameters including the distance traveled and heading.
Turning to capturing location and orientation information from sensors on USB and/or serial ports, the video, GPS and heading sensors will interface to the system through the USB or serial ports and/or video frame grabbers. A Panasonic® Toughbook® PC, for example, will host software to pull and retrieve information from the sensors on these ports.
“Meta tags” are used to associate the different data sets. “Meta tags” are a way to associate different data sets without requiring explicit relationships to be exercised. This system will utilize “meta tags” to relate features including the location and orientation of a viewpoint with its corresponding image. Time of day and unusual occurrences can also be “meta tagged”. It is part of the invention to include the heading information in the “meta tag” so that the direction of travel going north or south can determine the proper image. Other data can be elevation and annotations of unusual occurrences. Pre-determined commands can also be embedded in the data and are only displayed in proximity to annoted geo-referenced “meta tagged” markers.
Data is stored in a format that can be shared or combined with other geo-spatial information. The system will store the data in a format that can be used with other geo-spatial products such as those routinely used in the geo mapping industry with layers for features such as elevations, names of streets, rivers wireframes or shape files such as those from ESRI.
The present invention provides a way to share the data with others who will travel the same route at a later time. A client server model (data file management server) can be used to store and share the data amongst patrons. Data can be transferred between the client and server using networks or DVDs or other data media. Capture laptops will have DVD recording systems that will be able to publish DVDs for distribution to the server or directly to other users. The system design and topology will depend on what type of network infrastructure and bandwidth is available in the theatre of operation. The server will have a top down map view of the acquired vehicle paths. Any point on a path can be mouse clicked to provide the specific in vehicle view.
As an example, a PC was ruggedized to operate in military vehicles although other competitive laptop computers could be employed. Webcam and video sources can be used including images having a 9-degree field of view for small objects seen at 100 meters or a wider field of view for curved streets or urban environments.
It is believed that the mind's ability to register non-conforming images is vastly underestimated. By presenting images on a single split screen one on top of the other enables a viewer to immediately recognize irregularities and often times one can determine the relevance of such differences while ignoring different camera positions, fields of view, contrast, shadows and color differences between the images. Other techniques such as alternating the frames at various rates, super imposition, matting of features, or fusing of the imagery can also be used.
It is contemplated that a previously recorded view of a roadway including surrounding topography could be projected and compared to a real time view of the same region can be projected on the windshield of a moving vehicle as well. This may be useful for nighttime driving. However, a preferred embodiment is to provide a split screen whereby previously recorded video is compared with live video taken from a vehicle moving along a roadside. By providing one scene over another coordinated through the use of GPS coordinates “meta tagged” within a computing system, the vehicle operator can most readily detect differences between the “before and now” videos. The current embodiment relies upon commercial off-the-shelf GPS technology to retrieve a previously recorded reference view from a database that is nearly identical to the current “live” vehicle-mounted camera view. Again, ideally, both video views are simultaneously presented on a single display for visual comparison. Such a technique presents the two views in a manner that significantly augments and enhances the operator's natural ability to detect a “change” of new surface object. Semi-automated change detection software may also be employed to highlight disparities between the views. Such software is available commercially. In another variation, the rapid presentation between the before and after pictures creates an animation with the changed parts of the picture appearing to blink on and off.
In contemplating software applications, it is noted that single frames are available as geo-referenced data frames, but are used as top down map views. Several commercially available software packages are video based, but they generally use an MPEG compression protocol noting that only the initial frame could be geo-referenced and easily selectable without excessive decoding. MPEG compression further requires additional processing bandwidth and the utilization, again, of key frames. The use of key frames presents significant problems for accessing a specific frame within two points and would require significant database management tools. It was found that JPEG compression could be more viable by eliminating the need for key frame reference and complex data accessing and data management tools.
The present invention has been described as using video or thermal cameras to produce images. Different combinations can also be used for the before and current situation data sets such as a daylight video color camera for the acquisition and a black and white thermal sensor for the current night time image. In using thermal cameras, the present invention can be utilized at night while providing the necessary image recognition and image differentiation presentations for carrying out the present invention from the daytime image. Imagery can also be computer generated from wire frame and/or texture maps. Magnetic profiles, multi-spectral imagery, radar, sonar or ladar are also viable for use in practicing the present invention. Road like video, thermal HD, or low light NTSC video could also be employed as viable video sources noting that the key in practicing the present invention is the production of geo-referenced discreet raster based imagery.
It is contemplated that, as an embodiment, the data produced from geo-mapping a specific route can be stored in a format that can be shared or combined with other geo-spatial information. There have been geo-spatial extensions created for databases such as Oracle® sourced software or ESRI to make database access easier. The formats for exchanging information have been developed by organizations such as that available online at www.opengis.org. It is noted that the International Standard ISO 19136, the Geographic Information-Geography Markup Language (GML) contains instructions to store, combine and/or relate information with other geo-spatially reference data sets. There is a feature sub-type that has a coverage function over a spatial domain such as population and density, and an observation is considered to be something like a photo or measurement, noted with a time and possible other general values for the observation. The present invention intends to utilize the observation features as a template for data storage. Notations such as cautions can also be made that are referenced and stored with time captured and GPS location camera orientation noted as references. Noting that Open GIS specification includes portrayals of geographic information, map-type interfaces can be employed using symbols on suitable maps that display points of observation and thus will allow others to retrieve and display information interfaces created in the practice of the present invention.
Although the preferred embodiment in practicing the present invention contemplates a comparison between archival video taken from a vehicle and comparing it to real time video taken in substantially the same orientation, that is, from a moving vehicle, alternative video sources such as forward looking aerial and down looking recognizance can be employed herein. Skewed transformation and cropping can be employed to create a forward-looking aerial view into something akin to a view taken from a land-based vehicle. In doing so, aerial imagery must be employed in conjunction with processing not needed for land based image capture. For example, ego vectors on the aerial camera platform such as pitch, roll and yaw must be accounted for. Alternatively, the vehicle view can be transformed to look like a top down view which could then be used by automated change detection systems in workstations using down looking aerial video. This can be done using a line scanning approach to the sequence of frames. In alternative image manipulation techniques, on camera sensors such as inclinometers and digital compass information can also be tagged to a specific frame and used to calculate the morphing parameters to more closely register before and current imagery.
As noted previously, there are various hardware options available in practicing the present invention. For example, one could use a simple low cost web cam to provide the necessary imagery. Traditional cameras such as palmcorders with image stabilization could also be used effectively. Thermal imagery can be employed. Low light intensified cameras and low light video cameras can also be used as well as images produced by magnetic imagery, radar, sonar and rendered images from depth maps can additionally be employed. If analog video signals are to be employed (NTSC), a frame grabber card with onboard JPEG compression is desirable. This is all capable of being implemented into a personal computer. Alternatively, a video to USB or Analog to Digital converter can be employed for input sources. A Garmin® GPS device can be employed for geo referencing including the GPS coordinates and time of day or an inertial GPS system could be used.
It is also considered an aspect of the present invention to provide, on an as needed basis, various indicators of potential hazards on the video or appended audio archive. For example, voice commands, magnetic signatures, environmental sound, vehicle velocity, weather conditions, lighting and other environmental factors could be installed onto the memorialized depiction of a scene. On screen warnings of upcoming events, checkpoints, or decision points could be triggered by GPS positioning. In addition, vehicles can communicate with one another using DVD and server laptop data links as well as file management servers.
The software to be employed in practice in the invention must have certain obvious requirements. It must be capable of processing a live camera and sensor input while displaying output on a split screen. Although not required, the simultaneous recording and playback capability provides a system to automatically present the most recent data. The software must be capable of receiving GPS input for current vehicle positioning while selecting from a reference database of views the one view designated by closest GPS coordinates. Although not required, the same GPS coordinates can be employed to shift X and Y coordinates of the rendered view while displaying roadside threats, preferably in stereoscopic 3D based upon monoscopic 2D input signals. Better registration between the recorded and current image can be achieved using known techniques that consider the current camera ego motion and the acquired ego motion acquired from image interpolation or onboard sensors such as inclinometers, accelerometers or a digital compass. This onboard sensor information can be part of the meta-data fields embedded with each acquired image. This later feature is desirable for in depth examination. Again, as noted previously, as a preferred embodiment, the software can also utilize existing semi-automated change detection software to highlight on screen suspected hazards. The software code would utilize on board GPS devices in real time culled from an appropriate database of the most closely stored video frame. The closest GPS view is selected from the database as the onboard camera simultaneously displays both images. The images are ideally expanded horizontally (or squeezed vertically) to make the necessary X, Y adjustments based on road position and/or onboard sensors while recording images from onboard cameras to a storage device for future reference. Morphing software can also be used to improve the registration. It is also contemplated that the present invention will track the time that the video was captured and elevation and stored as this information as part of the “meta tag” data set. An XML schema will provide an interface for such information.
As noted previously, real time change detection software can be employed in conjunction with the present invention. Standard Geo Referenced Data (ARC Info/GIS) information can be imported and exported. In addition change detection software can compliment the system. Use of such software can be of assistance to eliminate false positives thus making the present invention more viable to an untrained operator. Images can be displayed to the operator on HMDs, heads down displays, LCDs, projection and laptop screens.
Although the present invention has been fundamentally described in terms of its use as an aid in high-risk applications, the invention can also be used in consumer and industrial environments as well. For example, rural and suburban areas can be mapped and “meta tagged” with a GPS coordinates and stored in an appropriate library. In the event of a natural disaster, such as an earthquake where roadway surfaces and surrounding topography can be substantially altered and thus create a hazard, such alteration could be readily visualized through the use of the present invention.
Furthermore, a downlooking camera from a submarine or surface watercraft can be used to precisely navigate a channel and avoid hazards. It can also be used to better land an aircraft in unfamiliar terrain or enter a port and make precise turns in relation to visual objects such as buoys. Comparisons of objects such as power lines, road markers and painted lines, roadside vegetation, tunnels and movement of terrain can also be made. Use of this invention as a navigational aid during nighttime, or for documenting deliveries of equipment along a route can also be made. Precise positioning of a vehicle can be made utilizing the comparison of the perfect position previously recorded to the current position. For example determining when to turn into a channel can be precisely made by matching shoreline trees, docks, buoy positions previously recorded by an expert navigator can be compared to the current position. This same principal can be used by large trucks trying to enter narrow loading docks.
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A method of detecting a changed condition within a geographical space from a moving vehicle. Images of that geographic space are memorialized in conjunction with GPS coordinates together with its GPS coordinates. The same geographic space is traversed from the moving vehicle while accessing the route's GPS coordinates. The memorialized images are played back by coordinating the GPS data on a memorialized images with that of the traversed geographic space such that the memorialized images are viewed simultaneously with the geographic space being traversed. An observer traveling within the moving vehicle can compare the memorialized images with those being traversed in order to identify changed conditions.
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FIELD OF THE INVENTION
[0001] The invention relates to communications network security, and in particular to methods and apparatus for selectively accepting communication traffic in enforcing control over the establishment of communications connections.
BACKGROUND OF THE INVENTION
[0002] Communications services are provisioned between source and destination communications network nodes end-to-end.
[0003] A variety of transport protocols are used concurrently to provide communications traffic transport. Typically, the content exchanged between end communications network nodes is segmented into Protocol Data Units (PDUs) in order to benefit from transport bandwidth utilization efficiencies. PDUs generally have an internal structure in accordance with which each segment of content is sandwiched between PDU headers and PDU trailers. The PDU headers and trailers have corresponding: application layer specifiers, communications session specifiers, routing specifiers, switching specifiers, etc. The appending of PDU headers and PDU trailers is known as encapsulation. PDU header information is used to process PDUs in transport at communications network nodes to effect the conveyance thereof in the associated communications network.
[0004] Consider, for example the use of the Internet Protocol (IP) as a transport protocol. The IP protocol operates in accordance with an interconnection hierarchy akin to the Open Systems Interconnection (OSI) Hierarchy. Data network nodes typically interconnect at the Physical Layer 1 , PDUs are typically switched at the Data Link Layer 2 , routing is typically provided at the Network Layer 3 , transport control is typically provided by a Transport Control Protocol (TCP) or a User Datagram Protocol (UDP) at Layer 4 , end-to-end sessions are typically controlled at Layer 5 , data format conversion is typically performed at Layer 6 , and applications enabling end user services operate at Layer 7 . Electronic content is exchanged end-to-end between applications.
[0005] Data segment payloads are assembled into PDUs by passing each payload segment to progressively lower OSI Layers. An increasing amount of session, connection, transport control, routing, switching etc. information is added to the payload segment by encapsulating higher layer PDUs with lower layer PDU headers and trailers. The resulting PDU is then sent over a physical link to a next network node toward a destination end network node. In processing PDUs at intermediary network nodes in the transport path, successive layers of headers are shed (decapsulation) depending on the transport services needed. Once the PDU is processed, it is encapsulated again and sent over another physical link towards another network node in the transport path. PDUs are also used to convey signaling information to effect connectivity end-to-end.
[0006] Each network node has a network address. End node network addresses are specified in PDU headers to enable routing and switching of each PDU at transport nodes while in transport. Each electronic service has a unique electronic service code to differentiate between electronic services. Electronic service codes are specified in “Assigned Numbers” Request For Comment (RFC) 1700 , or a more recent equivalent, and incorporated herein by reference. Each electronic service makes use of logical connection sockets which are specified in PDU headers as binding points in support of logical communications connections end-to-end. Each electronic service offered makes use of assigned logical communications sockets. Standard logical communications socket number assignments are also specified in the above mentioned “Assigned Numbers” RFC1700, or a more recent equivalent, for standard services. User logical communications socket numbers are also made available to applications on a need-to-use basis. Connectivity for simple electronic services may be achieved using an electronic service code and the corresponding logical socket number(s).
[0007] To effect the conveyance of signaling information, various PDU header/trailer specifiers are used to specify signaling flag values. Signaling flags may be conveyed either by special purpose signaling PDUs (typical of connection establishment) or content payload bearing PDUs as specified in the transport protocols used.
[0008] The conveyance of communications traffic often involves an interconnected conglomeration of public transport networks such as the Internet. Various portions of the Internet are managed by a corresponding variety of communications network service providers known as carriers. Carriers provide data transport services to customers. Customers include individual users and electronic service providers.
[0009] Customers are said to connect at the edge of transport networks via edge communications network equipment. Customer private networks typically make use of shared data transport technologies enabling unfettered exchange of information therewithin. A clash of communications traffic transport requirements exists because customers require interconnectivity over carrier networks while, at the same time, the same customers, require the protection of closely held information. Therefore, in provisioning communications services there is a need to effect control over communications traffic on edge.
[0010] Edge communications network equipment includes: bridges, routers, switches, aggregators/deaggregators, firewalls, gateways, etc. each having provider equipment and customer premise equipment varieties. Edge communications network equipment provide(s) severally or in combination a variety of functions including selective data traffic transport across a communications uplink/downlink between a private customer node/network and a public carrier network.
[0011] A firewall is a typical edge network node enforcing secure access. A firewall is a filtering gateway (sentry) adapted to sift traffic transported between a public side and a private side thereof. Physical connectivity with a carrier network is made from the public side and physical connectivity with a private customer node/network is made from the private side. Rogue communications network nodes and/or users seeking access from the public side to the private side, must be identified and their access blocked. Bona fide electronic service users accessing electronic services from the public side must be allowed controlled access to the private side. Communications service abusive network nodes and/or abusive users on the private side must be prevented from monopolizing communications resources. Well behaving communications network nodes and/or conscientious users on the private side must be allowed controlled access to the public side. In performing the sentry role, filtering gateways: monitor communications traffic patterns, determine a measure of adherence to a predefined communications regimen, and enforce control over communications traffic in accordance with the predefined communications regimen.
[0012] Prior approaches in effecting communications traffic acceptance selectivity operate either on a per-PDU basis (PDU filtering solutions), or on a per-communication-session basis (session state inspection solutions). The former lends itself to hardware implementation, while the later requires software implementation. Each one of these two differing approaches has benefits and shortcomings, and both have enjoyed an extensive research and application in the field.
[0013] Prior art PDU filtering implementations effect PDU acceptance selectivity by operating at the lower layers of the OSI hierarchy. PDU filtering gateways only process information specified in PDU headers below the session layer. PDU filtering gateways are regarded as very efficient in handling data traffic. The efficiency comes from the fact that information about session states is not used in effecting PDU acceptance selectivity. PDU filtering gateways therefore can be implemented in communications network nodes having minimal resources and therefore at minimal costs. PDU filtering implementations are therefore very well adapted to enforce PDU traffic acceptance selectivity in support of electronic service provisioning by operating on known values of a known group of PDU header specifiers. However, not all provisioned electronic service traffic may be controlled effectively by exclusive inspection of PDU headers below the session layer.
[0014] Prior art implementations effecting communications traffic acceptance selectivity on a per-communication-session basis, take into account session information derived from PDU headers corresponding to all layers of the OSI hierarchy and perhaps information derived from the PDU payload itself. Acceptance control based on session state inspection benefits from a fine acceptance selectivity enforcement. Such implementations incur comparatively large operational overheads in determining session states, and require large memory storage resources to track session states for a large number of communications sessions. Some implementations go as far as employing electronic service proxies which interpret conveyed PDUs in their entirety to extract session state information.
[0015] PDU filtering gateways typically employ hardcoded firmware and/or hardware enabling the inspection of PDU headers. For simple electronic services only a service code and two corresponding logical sockets are needed to be known to a particular PDU filtering gateway to effect full traffic acceptance control. For complex electronic services very little control may be effected based only on this information.
[0016] Problems with the above mentioned implementations may perhaps be best described via an example. Although a variety of electronic services exist, the FTP service is a most representative service to be supported. FTP stands for File Transfer Protocol—name which refers both to an actual file transfer protocol operating at OSI Layers 4 - 5 - 6 , and also refers to an application operating at OSI Layer 7 . The use of the FTP service is widespread from communications network node configuration management to Internet content downloading. A description of the FTP protocol is provided in RFC959 which is incorporated herein by reference. For the FTP service, a single electronic service code is defined.
[0017] An FTP session involves the use of multiple communication connections. The FTP protocol specifies the use of at least one control channel and at least one data channel to effect transfer of electronic content between communications network nodes. A default logical socket is defined for the control channel connection, and multiple varying logical socket numbers may be used, as required at run-time, for dynamically established data channel connections.
[0018] From a point of view of a particular edge communications network node, FTP services are initiated by establishing at least one control channel while the at lest one data channel typically does, but does not necessarily need to, involve the particular edge communications network node. The following represent exemplary FTP scenarios:
[0019] the transfer of a file across the edge communications network node: both the control channel and the data channel(s) are established via the edge communications network node;
[0020] the transfer of multiple files between two network nodes across the edge communications network node using a data channel and multiple data channels for transferring the files (not necessarily a one-to-one correspondence between the multiple files to be transferred and the number of data channel connections used);
[0021] a user from a network node on one side of the edge communications network node needs to synchronize two content servers on the other side: a control channel needs to be established to each content server via the edge communications network node, while the data connection is established between the content servers not involving the edge communications network node at all; and
[0022] a user from a network node on one side of the edge communications network node needs to synchronize two content servers one of which is on the private side and the other on the public side: a control channel needs to be established between the user's network node and the server on the opposite side of the edge network node, while the data connection(s) is/are established between the servers—all connections need involve the edge network node.
[0023] A characteristic of the FTP service is that connections, especially the data channel connections, are established dynamically, the particular FTP session associations of which may be determined only by inspection of Layer 7 information.
[0024] The use of multiple varying logical socket numbers in FTP service provisioning enables only the provisioning of rudimentary PDU filtering, which may only be based on the FTP service code, characterized by either full blocking of all FTP traffic or acceptance of all traffic purporting to be FTP traffic. Full blocking of FTP traffic is detrimental to the provision of this ubiquitous electronic service, while unrestricted access of all FTP traffic defeats the purpose of acceptance control enforcement especially considering that FTP traffic is bandwidth intensive.
[0025] Further, the hardware/firmware coding of PDU filtering gateway devices leads to equipment obsolescence as new electronic services are developed and deployed.
[0026] The information needed to determine what communication socket need be opened for each data channel is conveyed in the control channel.
[0027] In accordance with the prior art, in order to implement dynamic control over the data channels, the filtering gateway must inspect the payloads of the FTP PDUs exchanged over the control channel to determine session states. While incurring high processing overheads in performing session state inspection, session state inspection gateways can enforce enhanced traffic acceptance control for supported electronic services.
[0028] Electronic service developers do not necessarily code corresponding session state inspection gateways. Session state inspection gateways are coded by third parties. An exposure to session state inspection solution obsolescence exists as electronic service development and deployment is always ahead of session state inspection gateway development and deployment. Software solution coding used to implement the session state inspection gateways itself suffers from a high development and maintenance overhead to address solution obsolescence.
[0029] Coding efforts in developing and deploying software session state inspection gateways are subject to coding errors. Errors in session state inspection gateway application code impacts the ability to provision electronic services. Furthermore, the session state inspection overhead leads to a reduction in PDU transfer throughput across the session state inspection gateway when compared to the PDU filtering gateways.
[0030] Some communication services provisioning environments cannot justify employing session state inspection gateways while prior art hardcoded PDU filtering techniques are inadequate to provide traffic acceptance control for ubiquitous electronic services such as FTP.
[0031] There therefore is a need to provide filtering gateways and methods addressing the above mentioned problems.
SUMMARY OF THE INVENTION
[0032] In accordance with an aspect of the invention, a Protocol Data Unit (PDU) filtering gateway is provided. A sentry rule storage holds a plurality of sentry filtering rules. A dynamic rule storage holds a plurality of dynamic filtering rules. An extractor inspects a received PDU received via one of a private port and a public port and uses extracted PDU information to formulate a PDU acceptance query. A comparator subjects the PDU acceptance query to a combination of dynamic filtering rules and sentry filtering rules. And, a forwarder selectively accepts the PDU based on results of processing the PDU acceptance query. Each sentry filtering rule is specified for a PDU conveyance direction of an allowed connection establishment. A rule match between the PDU acceptance query corresponding to a SYN PDU, and a sentry filtering rule, generates at least one dynamic filtering rule for allowing conveyance of subsequent PDUs across the PDU filtering gateway bidirectionally, otherwise the conveyance of PDUs in the opposite direction being prevented.
[0033] In accordance with another aspect of the invention, each dynamic filtering rule specification includes: an origination network node address specifier, a destination network node address specifier, an origination logical socket range specifier, and a destination logical socket range specifier. A rule match between the PDU acceptance query corresponding to a SYN PDU, and a sentry filtering rule, generates at least one dynamic filtering rule. The dynamic filtering rule selectively allows conveyance of subsequent PDUs, across the PDU filtering gateway, for a plurality of connections using at least one origination logical socket in the origination logical socket range and at least one destination logical socket in the destination logical socket range thereby enabling support for dynamic callback services. Otherwise the conveyance of the subsequent PDUs is prevented.
[0034] In accordance with a further aspect of the invention, a method of filtering Payload Date Units (PDUs) in a PDU filtering gateway is provided. A PDU acceptance query is formed based on PDU information extracted from a received PDU. The PDU acceptance query is subjected to at least one sentry filtering rule. At least one dynamic filtering rule is selectively generated if the PDU acceptance query corresponds to a SYN PDU, and the PDU acceptance query matches a sentry filtering rule. The received PDU is selectively accepted based on results of processing the PDU acceptance query. With each sentry filtering rule being specified for a PDU conveyance direction of an allowed connection establishment, the at least one generated dynamic filtering rule selectively allows the conveyance of subsequent PDUs associated with the established connection, across the PDU filtering gateway, bidirectionally. Otherwise the conveyance of PDUs in the opposite direction is prevented.
[0035] In accordance with yet another aspect of the invention, in generating a dynamic filtering rule, the method includes further steps. An origination network address specifier of the generated dynamic filtering rule is populated with a first specific network address extracted from a received PDU. A destination network address specifier of the generated dynamic filtering rule is populated with a second specific network address extracted from the received PDU. An origination logical socket range specifier of the generated dynamic filtering rule is populated with at least one origination logical socket value corresponding to an allowed electronic service specification extracted from the PDU. And, a destination logical socket range specifier of the generated dynamic filtering rule is populated with at least one destination logical socket value corresponding to the allowed electronic service specification extracted from the PDU. Populating the origination and destination logical socket range specifiers with specific destination logical socket values, enables controlled selective acceptance of PDUs associated with at least one additional connection having the same allowed electronic service specification, between the first and second network addresses thereby providing support for dynamic callback services.
[0036] The advantages are derived from a run-time configurable, dynamic time-sensitive traffic acceptance control at reduced implementation costs. A variety of data services may be accommodated providing a resistance to obsolescence for communications network equipment implementing these techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The features and advantages of the invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached diagrams wherein:
[0038] [0038]FIG. 1 is a schematic diagram showing cooperating elements implementing an exemplary PDU filtering gateway and process steps implementing communications traffic acceptance selectivity in accordance with an exemplary embodiment of the invention
[0039] It will be noted that in the attached diagram like features bear similar labels.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0040] The operation of the File Transfer Protocol (FTP) service is exemplary of what is known as dynamic callback functionality. For certainty, the establishment of the control channel connection may lead to the establishment of other related connections including a multitude of data channel connections.
[0041] In accordance with an exemplary embodiment of the invention, support for dynamic callback functionality is implemented in an improved PDU filtering gateway.
[0042] In accordance with the exemplary embodiment of the invention, a dynamic callback filtering provides a simple mechanism for a PDU filtering gateway to support electronic services that dynamically open connections without requiring session state inspection (application layer information) of PDUs and storage of communications session state information. PDU filtering gateways are coded with the ability to: detect connection establishment signaling, determine connectivity states, and enforce access control over logical communications sockets.
[0043] Connection state determination involves tracking signaling information conveyed typically in OSI Layer 4 headers specified by the exemplary use of the Transport Control Protocol (TCP), and the User Datagram Protocol (UDP) transfer protocols.
[0044] In accordance with the exemplary embodiment of the invention, the degree to which connectivity state tracking is performed enables the determination of connection establishment and teardown.
[0045] Typically, each communications connection is established via signaling sequences known as handshakes. To establish a bidirectional TCP/IP connection, a three-way handshake is used:
[0046] A connection originator node first sends a synchronization request via a SYN PDU to an intended destination network node to establish a unidirectional connection;
[0047] The destination network node acknowledges the establishment of the originating unidirectional connection and proceeds to request establishment of the second unidirectional connection from the destination node to the originator node by sending back an acknowledgement and synchronization request: SYN/ACK PDU; and
[0048] The originator node acknowledges the establishment of the second unidirectional connection, via an ACK PDU, to complete the bidirectional connection. Tearing down of established TCP/IP connections can be initiated by any one end network node. Connection teardown typically involves sending a connection reset request (RST PDU) or a finish announcement (FIN PDU). Other signals my be used without departing from the spirit of the invention.
[0049] In employing the UDP protocol, successful transport of a first PDU between an originator network node and a destination network node is representative of a unidirectional connection existing between the network nodes.
[0050] In accordance with the exemplary embodiment of the invention, an improved dynamic callback PDU filtering gateway is provided with the ability to effect traffic acceptance in accordance with callback filtering rules. Each callback filtering rule states inter alia that, if a connection is established through the dynamic callback PDU filtering gateway between two end nodes, then at least one connection will be allowed to be established between the same two end nodes using at least one of a specific group of sockets (within a specific period of time). Therefore, improved traffic acceptance control for dynamic callback electronic services may be supported using PDU filtering techniques.
[0051] In accordance with the exemplary implementation, enhanced support for dynamic callback filtering is provided to effect traffic acceptance in accordance with sentry filtering rules. Each sentry filtering rule states inter alia, that if a PDU requesting the establishment of a communication connection matches the conditions of a session PDU filtering rule in a particular PDU transport direction across the exemplary dynamic callback PDU filtering gateway, electronic service specific traffic flow in the opposite transport direction is to be allowed thereafter, and not before, between the specific destination and origination network addresses. Sentry filtering rules have a directional specification related to the acceptance of PDU traffic across the dynamic callback PDU filtering gateway: private→public/public→private. As will be shown herein below, the sentry rules may have a unidirectional or a bi-directional effect once triggered.
[0052] Each sentry PDU filtering rule includes the following specifiers:
[0053] an Origination Network Address Range;
[0054] a Destination Network Address Range;
[0055] a Protocol;
[0056] an Origination Logical Socket Range;
[0057] a Destination Logical Socket Range;
[0058] a rule Type; and (Timeout).
[0059] Network Address Ranges may include: one network address, a subnet address, at least one wild card, address range mnemonics, etc. Address range mnemonics include:
[0060] ANY—referring to any network address;
[0061] MAP—referring to any network address specified in an associated list;
[0062] VPN—referring to network addresses of nodes participating in a Virtual Private Network (VPN);
[0063] PRIVATE—referring to any network address on the private side; and
[0064] PUBLIC—referring to any network address on the public side.
[0065] An Address Range mnemonic definition facility may be provided. An address MAP definition facility may also be provided.
[0066] The Protocol specifier may hold supported service code values specified in the above mentioned “Assigned Numbers” RFC1700, or a more recent equivalent, as well as supported service code mnemonics including:
[0067] ANY—referring to any service code regardless of support thereof;
[0068] ALL—referring to all supported service codes; and
[0069] “specific electronic service mnemonics”: FTP, TCP, UDP, ICMP (Internet Control Message Protocol), etc.
[0070] A facility may be provided for the definition of protocol specification mnemonics reducing solution obsolescence. Another facility may be provided for the definition of SMAP(s).
[0071] The Logical Socket Ranges specifiers hold the logical connection socket ranges associated with the origination and destination of traffic, respectively. The Socket Range specifiers may be populated with logical socket values specified in the above mentioned “Assigned Numbers” RFC1700, or a more recent equivalent, as well with supported service code mnemonics including:
[0072] ANY—referring to any service code regardless of support thereof;
[0073] ALL—referring to all supported service codes; and
[0074] “specific electronic service mnemonics”: FTP, TCP, UDP, ICMP, etc.
[0075] A facility may be provided for the definition of logical socket specification mnemonics preventing solution obsolescence.
[0076] The Type specifier indicates how the rule should be interpreted. Exemplary valid types include:
[0077] ALLOW—enables unhindered unidirectional transfer of inspected rule triggering PDUs across the enhanced PDU filtering gateway with very little processing overhead;
[0078] DENY—blocks unidirectional transfer of triggering PDUs with very little processing overhead;
[0079] CONNECTION—specifies control over bidirectional traffic when an allowed connection is initiated in the direction specified in the sentry filtering rule: PDU traffic is not accepted in the opposite direction until the connection is initiated, and PDU traffic is not accepted in the opposite direction after the connection has been terminated; and
[0080] CALLBACK—specifies control over bi-directional traffic for multiple (related) connections in support of dynamic callback electronic services: once a connection is established, as exemplary described in the paragraph above, additional connections are permitted to be established between the network nodes of the initial connection.
[0081] In referring to FIG. 1 exemplary elements will are labeled with 100-series labels while exemplary process steps will be labeled with 200-series labels.
[0082] In accordance with the exemplary embodiment of the invention, sentry filtering rules are specified via a human readable sentry filtering rules file 110 . The use of the human readable sentry filtering rules file 110 provides support for the configuration of the exemplary dynamic callback PDU filtering gateway 100 . Support for additional electronic services may be provided via additional configuration specified via additional sentry filtering rules. The sentry filtering rules file 110 is loaded 220 , parsed 222 by a parser 120 , and the specified traffic acceptance regiment is stored 224 in retrievable storage 130 for subsequent access. The retrievable storage 130 may include, but is not limited to, a sentry rule table 130 .
[0083] Certain directives, specified via a configuration (or definitions) file 112 , may be used to effect the definition of the various mnemonics and Map(s) mentioned above. A command may be issued to the dynamic callback PDU filtering gateway 100 to store a current PDU acceptance discipline in a sentry filtering rules file 110 , as well another command may by issued to store the current configuration of the dynamic callback PDU filtering gateway 100 in the configurations file 112 .
[0084] The sentry filtering rules are intended to have a governing effect on the PDU acceptance discipline, and as presented herein above, preferably describe the traffic acceptance regimen generically. For example, the use of Network Address mnemonics helps in defining a compact acceptance discipline.
[0085] Generally, ALLOW sentry filtering rules are specified in corresponding pairs to enable bi-directional transfer of PDUs. The ALLOW and DENY sentry filtering rule types enable backward compatibility with prior art PDU filtering functionality. Once triggered, the ALLOW and DENY sentry filtering rules cause the specification and activation of corresponding dynamic filtering rules enabling traffic acceptance enforcement in the transport direction of the triggering PDU.
[0086] Directional CONNECTION and CALLBACK sentry filtering rules, when triggered, generate additional dynamic filtering rules enabling associated traffic acceptance enforcement in the same and/or opposite transport direction as that of the triggering PDU. Dynamic filtering rules created on triggering CONNECTION and CALLBACK sentry filtering rues are removed when connections terminate.
[0087] Dynamic filtering rules are intended to effect specific PDU acceptance selectivity. The dynamic filtering rules may have a format similar to the sentry filtering rule format presented above and stored in a dynamic rules table 140 . In accordance with the exemplary embodiment of the invention, the specification of the dynamic filtering rules differs from the specification of the sentry filtering rules in:
[0088] The Origination and Destination Network Node Address specifiers are populated with specific end network node addresses;
[0089] The Protocol specifier is populated with the specific protocol value corresponding to the triggering PDU;
[0090] The Origination and Destination Logical Socket Ranges are populated with the specific logical socket values associated with the service code corresponding to the triggering PDU; and
[0091] The rule Type is preferably either ALLOW or DENY although the CONNECTION Type may be used to specify dynamic filtering rules more compactly.
[0092] For example, in providing traffic acceptance control support for web content delivery services, user network nodes from the public side are to be given access to a web content server network node having a network address WebServerADDR on the private side. The following exemplary sentry filtering rule:
[0093] PUBLIC, WebServerADDR, TCP, ANY, HTTP, CONNECTION
[0094] enables the user from the public side to establish a communication session with the web server located on the private side.
[0095] In establishing a web browsing connection, a user network node sends a SYN PDU bearing: a UserNodeAddress, the WebServerADDR, the HyperText Transfer Protocol (HTTP) service code, and connection socket specifications. The SYN PDU is conveyed 230 towards the dynamic callback PDU filtering gateway 100 .
[0096] The SYN PDU is received 232 via the public physical port 150 of the dynamic callback PDU filtering gateway 100 and provided to an extractor block 160 . The extractor block 160 monitors communications traffic patterns by extracting header specifier values. The extractor block 160 forms a PDU acceptance query 234 , and submits the query 234 to a comparator block 170 .
[0097] The comparator block 170 determines a measure of adherence to the predefined communications regimen specified in the sentry rules table 130 and the dynamic rules table 140 . The comparator block 170 performs a rule match query 240 on the dynamic filtering rules in the dynamic rules table 140 using the header information extracted from the PDU.
[0098] The rule match query 240 may result in a rule match which specifies discarding the PDU. The PDU drop result 242 is conveyed to a forwarder block 180 which discards the PDU 244 . The PDU including its payload is available 236 form the extractor block 160 via methods and techniques beyond the scope of the present description without limiting the invention.
[0099] The rule match query 240 may result in a rule match which specifies the acceptance of the PDU. The PDU accept result 246 is provided to the forwarder block 180 . The forwarder block 180 transfers 248 the PDU across the dynamic callback PDU filtering gateway 100 and causes its forwarding over the private port 152 . Ultimately the accepted PDU is transported 250 over the private network to the web content server.
[0100] If the received PDU is a SYN PDU, it is likely that the rule match query 240 performed on the dynamic rules table 140 will result in a non-hit event which is expected as the SYN PDU is the first PDU of the exemplary new web browsing connection. The rule match non-hit event is notified 260 to the comparator block 170 .
[0101] The comparator block 170 performs a continued rule match query 262 on the sentry filtering rules in the sentry rules table 130 using the header information extracted from the PDU.
[0102] The continued rule match query 262 may result in a rule match which specifies discarding the PDU. The PDU drop result 264 is conveyed to the forwarder block 180 which discards the PDU 244 .
[0103] The continued rule match query 262 may result in a rule match which specifies the acceptance of the PDU. The PDU accept result 266 is provided to the forwarder block 180 . As an intended side effect, at least one dynamic filtering rule is created 268 and stored in the dynamic rules table 140 . The forwarder block 180 transfers 248 the PDU across the dynamic callback PDU filtering gateway 100 and causes its forwarding over the private port 152 . Ultimately the accepted PDU is transported 250 over the private network to the web content server.
[0104] In accordance with the example, the processing of the SYN PDU results in the creation 268 of the following unidirectional dynamic filtering rules to allow the PDU transfers across the dynamic callback PDU filtering gateway 100 for a single bidirectional connection:
[0105] UserNodeADDR, ServerADDR, TCP, userSocketOut, HTTP, ALLOW; and
[0106] ServerADDR, UserNodeADDR, TCP, HTTP, userSocketIn, ALLOW.
[0107] Should the extractor 160 process an RST PDU or a FIN PDU for the web browsing connection, the extractor 160 causes the deletion 238 of the corresponding dynamic filtering rules.
[0108] The generated dynamic filtering rules correspond to rules that would need to be setup for simple PDU filtering. The enhancement comes from the fact that before the SYN PDU is received no connections are allowed in the opposite transport direction of the SYN PDU whatsoever. Nor are connections allowed in the opposite direction after connection termination representing a further security access enhancement.
[0109] The storage 224 of the sentry filtering rules in the retrievable storage 130 may be subject to a storage sequence akin to the order in which the sentry filtering rules were specified in the filtering rules file 110 . Sentry rules may be triggered on a first-matched basis. Non-trigger instances 264 lead to discarding the subject PDU. Non-trigger events 260 in inspecting the dynamic rules table 140 simply cause the inspection of the sentry rules table 130 .
[0110] In accordance with the specification of the FTP protocol the control channel employs a TCP connection. The following exemplary filtering rule would enable users on the private side to access any FTP servers on the public side:
[0111] PRIVATE, PUBLIC, TCP, ANY, FTP, CALLBACK, ALLOW.
[0112] A received FTP SYN PDU matching the filtering rule will trigger the dynamic callback PDU filtering gateway 100 to generate a pair of ALLOW dynamic filtering rules for accessing a particular FTP server having a node address FTPserverADDR:
[0113] UserNodeADDR, FTPserverADDR, TCP, ClientControlSocket, ServerControlSocket;
[0114] FTPserverADDR, UserNodeADDR, TCP, ServerControlSocket, ClientControlSocket;
[0115] for the control channel connection. In order to provide support for the dynamic callback functionality of the FTP protocol a range of logical sockets A to N are made available to be used for FTP services. As soon as the control channel connection is established, the following ALLOW dynamic filtering rule is added 268 to the dynamic rules table 140 :
[0116] FTPserverADDR, UserNodeADDR, TCP, 1024-65535, 1024-65535, CONNECTION.
[0117] This allows the FTP server to request establishment of data channel connections back to the UserNodeADDR using user logical sockets in the FTP allowed range of logical sockets. As each data channel connection is established, specific ALLOW rules are generated 268 :
[0118] UserNodeADDR, FTPserverADDR, TCP, UserSocketA, FTPsocketA, ALLOW;
[0119] FTPserverADDR, UserNodeADDR, TCP, FTPsocketA, UserSocketA, ALLOW;
[0120] UserNodeADDR, FTPserverADDR, TCP, UserSocketB, FTPsocketB, ALLOW;
[0121] FTPserverADDR, UserNodeADDR, TCP, FTPsocketB, UserSocketB, ALLOW;
[0122] (etc.)
[0123] The entire range of logical sockets may or may not actually be used. The receipt and transfer of an RST or a FIN PDU in relation to the control channel connection causes the deletion 238 of all dynamic filtering rules for the FTP service between the UserNodeADDR and the FTPserverADDR.
[0124] The exemplary functionality presented enables PDU filtering gateways to support dynamic callback functionality at reduced costs compared to session state inspection gateways.
[0125] As the sentry filtering rules specified to have a governing effect on PDU traffic acceptance are inspected, and interpreted only once at connection establishment, the use of dynamic filtering rules having a specific effect on each connection provides a reduction in processing overheads.
[0126] Such implementations may also be shown to utilize comparatively less resources when compared to session state inspection filtering techniques. With careful design a dynamic filtering rule may be expressed in 32 bytes, or less, enabling tens of thousands of connections to be established and processed on relatively modest equipment.
[0127] Therefore, without tracking communications session states, further traffic acceptance control may be enforced by a configurable control over the use of logical communications sockets.
[0128] In relation to the provision of FTP services the need to examine control channel PDU payloads is reduced and may ultimately be eliminated dependent on which FTP scenarios are to be supported by a particular implementation.
[0129] A security hole exists in enabling access to a range of logical sockets. Otherwise unauthorized access is given to other applications purporting to be FTP applications using the allowed logical socket associations to establish communication sessions between the communicating network nodes. A closer control may of course be provided by session state inspection of PDUs at excessive implementation and maintenance costs.
[0130] In accordance with the exemplary embodiment of the invention, the exposure to the security hole is be minimized by timing-out the dynamic filtering rules.
[0131] The Timeout specifier is used to set time constraints within which establishment of allowed connections is expected. Values used may be based on the Protocol and/or Type specifiers. A 0 (zero) value is used to indicate no timeout. If not specified, a default timeout may be used.
[0132] For example, each dynamic filtering rule is timed out independently and deleted if not used:
[0133] UserNodeADDR, FTPserverADDR, TCP, UserSocketA, FTPsocketA, ALLOW, 5 min;
[0134] FTPserverADDR, UserNodeADDR, TCP, FTPsocketA, UserSocketA, ALLOW, 5 min;
[0135] UserNodeADDR, FTPserverADDR, TCP, UserSocketB, FTPsocketB, ALLOW, 5 min;
[0136] FTPserverADDR, UserNodeADDR, TCP, FTPsocketB, UserSocketB, ALLOW, 5 min;
[0137] . . .
[0138] UserNodeADDR, FTPserverADDR, TCP, UserSocketN, FTPsocketN, ALLOW, 5 min;
[0139] FTPserverADDR, UserNodeADDR, TCP, FTPsocketN, UserSocketN, ALLOW, 5 min.
[0140] The Timeout values are decremented at regular intervals by a timer module 190 . Subsequently received PDUs matching the dynamic filtering rules update 292 respective Timeout values. If no PDUs are received by the dynamic callback PDU filtering gateway within the time period specified in the Timeout specifier then, the corresponding dynamic filtering rule is deleted 294 (for example on decrementing the Timeout value to 1).
[0141] The direction of PDU transport across the PDU filtering gateway is symmetric except for the case in which the PDU filtering gateway also supports processing of encrypted traffic, then only decrypted PDUs are subjected to the communications traffic acceptance discipline.
[0142] The embodiments presented are exemplary only and persons skilled in the art would appreciate that variations to the above described embodiments may be made without departing from the spirit of the invention. The scope of the invention is solely defined by the appended claims.
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A communications traffic acceptance control methods and a Protocol Data Unit (PDU) filtering gateway are presented. The PDU filtering gateway operates in accordance with a group of sentry filtering rules and on accepting PDU traffic. The enhanced PDU filtering gateway selectively generates at run-time additional dynamic filtering rules. Dynamic PDU acceptance control may be enforced on communications traffic in the same and/or the opposite conveyance direction as the first sentry filtering rule triggering PDU. Dynamic PDU acceptance control may also provide time constraint enforcement on traffic acceptance. Advantages are derived from a dynamic PDU acceptance control over connection establishment utilizing reduced resources. New data services may be accommodated via sentry filtering rule specifications providing resilience to equipment obsolescence and minimizing code maintenance overheads.
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FIELD OF THE INVENTION
[0001] The invention relates to a digital signal processing technique that changes the length of an audio signal and, thus, effectively its play-out speed. This is used in the professional market for frame rate conversion in the film industry or sound effects in music production. Furthermore, consumer electronics devices, like e.g. mp3-players, voice recorders or answering machines, make use of time scaling for fast forward or slow-motion audio play-out.
BACKGROUND OF THE INVENTION
[0002] The following list of applications for time-scaling audio signals can be found in Dorran et al., “A Comparison of Time-Domain Time-Scale Modification Algorithms,” AES 2006:
Fast browsing of speech material for digital libraries and distance learning Music and foreign language learning/teaching Fast/slow playback for telephone answering machines and Dictaphones Video-cinema standards conversion Audio Watermarking Accelerated aural reading for the blind Music composition Audio-video synchronization Audio data compression Diagnosis of cardiac disorders Editing audio/visual recordings for allocated timeslots within the radio/television industry Voice gender conversion Text-to-speech synthesis Lip synchronization and voice dubbing Prosody transplantation and karaoke
[0018] A way of realizing such a digital signal processing technique for audio signal length change is the so-called Waveform Similarity OverLap Add (WSOLA) approach. WSOLA is capable of producing time scaled output signals of high quality. The WSOLA output signal is constructed from blocks of a fixed length (typically around 20 ms). These blocks overlap by 50% so that a fixed cross-fade length is guaranteed. The next block appended to the output signal is the one that is, first, most similar to the block that would normally follow the current block and that, second, lies within a search window around the ideal position (as determined by the scaling factor). The deviation from the ideal position is thereby typically restricted to be less than 5 ms resulting in a search window of 10 ms in size.
[0019] Demol et al. describe in, “Efficient Non-Uniform Time-Scaling of Speech with WSOLA,” Speech and Computers (SPECOM), 2005, that WSOLA may also be extended to take the varying characteristics of the processed signal into account for by varying the scaling factor.
SUMMARY OF THE INVENTION
[0020] The invention aims at enhancing the WSOLA approach by proposing a method for time scaling a sequence of input signal values using a modified waveform similarity overlap add approach according to claim 1 and a device for time scaling a sequence of input signal values using a modified waveform similarity overlap add approach according to claim 9 .
[0021] According said method the waveform similarity overlap add approach is modified such that a maximized similarity is determined among similarity measures of sub-sequence pairs each comprising a sub-sequence to-be-matched from a input window and a matching sub-sequence from a search window wherein said sub-sequence pairs comprise at least two sub-sequence pairs of which a first pair comprises a first sub-sequence to-be-matched and a second pair comprises a different second sub-sequence to-be-matched.
[0022] The input window allows for finding sub-sequence pairs with higher similarity than with a WSOLA approach based on a single sub-sequence to-be-matched. This results in less perceivable artefacts.
[0023] In an embodiment, said first pair comprises a first matching sub-sequences and said second pair comprises different second matching sub-sequences.
[0024] In another embodiment, said first pair and said second pair comprise a same matching sub-sequence.
[0025] Advantageously, modification of said waveform similarity overlap add approach comprises copying sub-sequences until an accumulated temporal deviation which results from said copying is equal to or larger than a predetermined minimum temporal deviation, said accumulated temporal deviation depending on an accumulated temporal duration of the copied sub-sequences and an aspired time scaling factor.
[0026] This reduces the number of splice points and thus the audibility of time scaling.
[0027] The similarity measure of each sub-sequence pair may comprise a weighting which takes into account the temporal distance between the sub-sequences of the pair.
[0028] Taking the temporal distance into account enables to bias the WSOLA approach towards preferred temporal distances.
[0029] For instance, in an embodiment, the similarity is weighted such that it is biased towards larger temporal distances.
[0030] This allows for appending longer sub-sequences which in turn makes less splicing points necessary.
[0031] In yet another embodiment of the method, the similarity is weighted such that it is biased towards temporal distances corresponding to an aspired time scaling factor.
[0032] Then, even parts of the time scaled sequence reflect the time scaling factor well.
[0033] In yet a further embodiment, the input window is determined such that it comprises at least one pause signal segment.
[0034] Splicing is known to be computationally simple for signal pauses.
[0035] And in even yet a further embodiment, the input window is determined such that it does not comprise any transient signal segment.
[0036] Splicing is known to be computationally difficult for transient signal segments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Exemplary embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description.
[0038] In the figures:
[0039] FIG. 1 depicts an exemplary original sample sequence and an exemplary time scaled sample sequence and
[0040] FIG. 2 depicts exemplary weighting functions.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The exemplary embodiment of the invention realizes time scaling according to a time scaling factor a in a two phase process. In one of the two phases, samples of an original sample sequence ORIG are simply copied to a time-scaled sample sequence SCLD.
[0042] Let a time scaling difference be equal to the absolute of 1−α. Then, the duration of each copied sample deviates from the duration of an ideal time-scaled sample by the duration of one original sample D OS times the time scaling difference. Copying L samples therefore results in an accumulated temporal deviation of:
[0000] Δ L =L·D OS ·|α−1═+Δ 0
[0000] wherein Δ 0 is an initial temporal deviation which may be zero or which may be neglected when determining the accumulated temporal deviation.
[0043] At least as many samples are copied that the accumulated temporal deviation exceeds a lower deviation threshold Δ min . And, at most as many samples are copied that the accumulated temporal deviation does not exceed an upper deviation threshold Δ max .
[0044] The lower deviation threshold Δ min ensures a minimal distance between splice points in the time scaled sample sequence. A small hop distance between splice points is problematic as the energy of audio signals tends to be concentrated in the low-frequency range so that the self-similarity function has a broad peak around zero. If Δ min is a lot smaller than this peak, the template matching is likely to decide for the border of the search window being closest to the ideal point several times in a row (until the summation of Δ min has surpassed the width of the above peak in the self-similarity function).In this case, the output signal will contain a concatenation of many small signal segments. The minimal distance corresponds to the cross-fade length between two copied blocks, i.e. N samples in the time-scaled signal. Ideally, N/α samples are used for forming these N samples in the time-scaled signal. This results in a lower deviation threshold Δ min in the original signal of:
[0000]
Δ
min
=
N
·
1
-
α
α
D
OS
[0045] Additionally, the lower deviation threshold Δ min may be determined such that it reaches at least a lower bound LB:
[0000]
Δ
min
=
max
(
LB
,
N
·
1
-
α
α
D
OS
)
[0046] Good results are achieved with LB=2 ms. Especially if α is small, the lower bounds LB helps preventing the introduction of artefacts.
[0047] The upper deviation threshold Δ max ensures a maximal distance between splice points in the time scaled sample sequence. The maximal distance limits accumulated temporal deviation Δ L and thus the length of contiguous sub-sequences of the input signal which are omitted or repeated. In turn, the audibility of artefacts due to repetition or omittance is limited too.
[0048] When copying results in the upper deviation threshold Δ max being met or just exceeded, processing enters a second phase. In the second phase, a modified WSOLA is performed. For a template subsequence of N would-be-copied-next samples in the original sample sequence SCLD, a template matching is performed to find candidate subsequence C* most suitable for splicing among candidate subsequences C 1 , . . . ,C*, . . . ,Ck within a search window MW in the original sample sequence ORIG. The template matching is based on a similarity measure like a correlation, a mean square difference or a mean absolute difference which is weighted with a weight W in dependence on the temporal difference Δt between the temporal position of the candidate subsequence and the template's position in the original sample sequence.
[0049] The weight W may further depend on an ideal temporal shift ITS of a candidate subsequence C 1 , . . . ,C*, . . . ,Ck, said ideal temporal shift ITS being determined by the candidate subsequence's temporal position in the original sample sequence ORIG and the time scaling factor.
[0050] Exemplary weighting functions WF 1 , WF 2 , WF 3 are schematically depicted in FIG. 2 .
[0051] The weighting function may be a linear function WF 1 , WF 2 such that the best match is biased towards those candidates which will result in a larger initial temporal deviation (retardation or pre-appearance) and thus in a larger signal segment when being appended next.
[0052] The weighting function may be a bell-shaped function WF 3 such that the best match is biased towards those candidates which will result in an initial temporal deviation which corresponds best to the ideal temporal shift ITS when being appended next.
[0053] Another weighting function is useful if a film comprising synchronized audio and video signals is time-scaled. The human perceptive system is adapted to situations in which a visual impression of an event is perceived earlier than a corresponding audible impression of said event. For instance, if someone is shouting from a distance the visual impression of this event is propagated at the speed of light to an observer while the shout is propagated at the speed of sound, only. So, a small retardation of the audio signal with respect to the video signal is likely to be ignored by the observer. But, a retardation of the audio signal which is that large that the audio signal does not fit the video signal anymore is an annoying artefact. Similarly annoying is any retardation of the video signal with respect to the audio signal.
[0054] Thus, a weighting function which depends on a time-scaling achieved for the video signal such that it is ensured that the time-scaled audio signal does not lead ahead of the time-scaled video signal and at the same time is not delayed too much may be beneficial. For instance, the bell-shaped function WF 3 may be centred on a shift position which ensures a small but not too large delay of the time-scaled audio signal with respect to the time-scaled video signal.
[0055] The template matching may further be performed for an subsequence comprising N last copied samples immediately preceding the sample last copied to the time-scaled sequence SCLD. The similarity between the last-but-one subsequence and its best matching template is compared with the similarity between the last subsequence and the last subsequence's best matching template wherein the similarities may or may not be weighted. The subsequence being associated with the larger weighted similarity is spliced or cross-faded with its best matching template in the time scaled sample sequence. Similarly, a set of subsequences comprising all subsequences B 1 , . . . , B*, . . . , Bn from a last-but-n subsequence to the last subsequence may be taken into account for maximizing the weighted similarity.
[0056] Thus the similarity measure is not only maximized for single potential splice point but for a whole set of potential splice points preferably lying dense in a input window SW. The result is a two-dimensional similarity function.
[0057] But, the additional computational effort for calculation of said two-dimensional similarity function remains limited.
[0058] For a template length of N samples and a search window width of K samples, the one-dimensional similarity function requires calculation of N*K multiplications or absolute/squared difference values etc. Then, K similarity values are determined by summing up N of the resulting values.
[0059] If α is closed to 1, a common search window could be used for all templates in the input window.
[0060] Then, the two-dimensional similarity function with a input window width of L requires calculation of (N+L)*K values and summing them up into L*K similarity values. Thus, the additional computational effort for the two-dimensional search grows linearly with the size of the search window.
[0061] Within the one-dimensional framework, K different similarities have to be determined while the two-dimensional framework requires calculation of L*K different similarities. But in the two dimensional framework, some of the similarities may be determined iteratively.
[0062] That is, a first sum of values determining a first similarity value of a first template with a first candidate differs only in one summand from a second sum of values determining a second similarity value of a second template with a second candidate wherein both, the second template and the second candidate, are shifted by one sample with respect to the first template respectively the first candidate.
[0063] From said L*K different similarities, only K+L similarities have to be determined from scratch, the remaining (K−1)*(L−1) similarities can be determined iteratively.
[0064] If a is much larger or much smaller than 1, a set of intersecting search windows, one per each template from the input window. Each of the search windows is centred at the point in time which corresponds to the ideal time shift of the corresponding template is used.
[0065] The input window SW may be determined such that it comprises at least one pause and/or at least one quasi-periodic signal segment. It is known that such signal segments provide good splicing points while transient signal segments are less suited for splicing or cross fading. Additionally or alternatively, the weighting of the similarity measure may be adapted such that it further or solely depends on the signal characteristics in the subsequences B 1 , . . . , B*, . . . , Bn wherein pausing and/or quasi-periodicity in segments to-be-spliced result in an increase of weight while transient signal characteristics result in a reduction of weight.
[0066] The pair of subsequences comprising a best matched subsequence B* from the input window SW and a best matching candidate subsequence C* from the search window MW for which the similarity is maximal, is used to generate samples of a cross-fade area CF of the time scaled signal SCLD.
[0067] The number of samples in the cross-fade area may correspond to the number of samples in one of the subsequences, such that all samples of the subsequences are used for cross-fading. Or, the number of samples in the cross-fade area is smaller, i.e., only some samples of the subsequences are used. For instance, the sub-sequence length corresponds to the length of a block or 2*N samples while the cross-fade area length corresponds to the length of half a block or N samples. Using subsequences longer than the cross-fade area may be advantageous for further reducing the audibility of splice points by biasing them towards the middle of phonemes.
[0068] There is an exemplary embodiment of the method for time scaling a sequence of signal values according to a time scaling factor, wherein said method comprises the step of time-scaling a preceding sub-sequence using a WSOLA approach and the step of time-scaling a consecutive sub-sequence using an interpolative approach.
[0069] In a further exemplary embodiment, the method comprises the steps of (a) forming subsequence pairs comprising a subsequence to-be-matched B 1 , B*, Bn and a matching subsequence C 1 , C*, Ck, (b) for each pair, determining a similarity between the subsequences comprised in the pair, (c) determining a preferred pair B*, C*, said preferred pair having a maximum similarity, (d) cross-fading the preferred matching subsequence with said preferred subsequence matched in the time scaled sequence SCLD, (e) determining the length of a to-be-copied subsequence by help of the preferred matching subsequence, (f) copying this subsequence to the time scaled sequence SCLD and returning to step (a), wherein the length of the to-be-copied subsequence depends on a threshold.
[0070] Preferably, step (b) comprises determining a weight dependent on the temporal distance between the subsequence to-be-matched and the matching subsequence of the pair.
[0071] In yet a further embodiment, step (e) comprises using the temporal factor and the temporal distance between the preferred matching subsequence and the preferred subsequence matched for determination of the length of the to-be-copied subsequence.
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The invention relates to a digital signal processing technique that changes the length of an audio signal and, thus, effectively its play-out speed. This is used for frame rate conversion or sound effects in music production. Time scaling may further be used for fast forward or slow-motion audio play-out.
According said method the waveform similarity overlap add approach is modified such that a maximized similarity is determined among similarity measures of sub-sequence pairs each comprising a sub-sequence to-be-matched from a input window and a matching sub-sequence from a search window wherein said sub-sequence pairs comprise at least two sub-sequence pairs of which a first pair comprises a first sub-sequence to-be-matched and a second pair comprises a different second sub-sequence to-be-matched.
The input window allows for finding sub-sequence pairs with higher similarity than with a WSOLA approach based on a single sub-sequence to-be-matched. This results in less perceivable artefacts.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of co-pending, commonly-owned U.S. patent application Ser. No. 10/611,769, which was filed on Jul. 1, 2003.
TECHNICAL AREA
[0002] The present invention relates to fabric-faced laminates for use as floor coverings.
BACKGROUND
[0003] Floor coverings are generally selected based upon a combination of factors including aesthetic features such as the look and feel of the floor covering and functional qualities such as retention of surface appearance, stain resistance, moisture resistance, ease of cleaning, and resistance to collection of dirt. For example, floor covering installations in high traffic areas or areas prone to moisture and stains such as kitchens generally use solid surface cover materials for the flooring or interior wall coverings such as wood, metal, marble, ceramic tile, vinyl or rubber. These products retain their surface appearance after heavy use and they are simple to keep clean. They also are resistant to stains and moisture, and less prone to harboring bacterial growth. However, these products lack the textile hand, softness or sound dampening qualities of textile products.
[0004] In installations where aesthetic qualities such as texture and softness are desired, products such as tufted, knit, knotted or woven structures, including velour or velvet are used. These products provide softness and cushion, a soft textile hand and a degree of abrasion and wear resistance. Compared to rigid solid surfaced products, however, these floor coverings are less durable, tend to lose their texture with heavy use, because the pile tends to mat or to be crushed with heavy traffic, tend to collect dust and dirt, provide spaces that allow the growth of bacteria, and are difficult to clean and sanitize.
[0005] Attempts have been made to create products having both the desired functional qualities of solid surface materials and the aesthetic qualities of textile or fabric materials. For example, hybrid structures with partially fibrous and partially solid faces are disclosed in U.S. Pat. No. 3,943,018. These hybrid structures, however, merely reduce but do not eliminate the limitations of regular tufted, velour, or flocked textile surfaces.
[0006] Other attempts provide flat or profiled, e.g., sculpted, surfaces containing fibrous layers impregnated with a plastic matrix. Examples of fibrous layers impregnated with a plastic matrix are disclosed in U.S. Pat. Nos. 4,035,215, 4,098,629, and 6,063,473. These floor coverings generally have surfaces with a semi-fibrous feel, and the spaces between the fibers may be sufficiently sealed to prevent bacterial penetration and dirt collection. In addition, these floor coverings also provide a higher matting resistance than regular upright-oriented fiber structures. However, these floor covering products largely have a stiff leathery appearance rather than a soft textile feel, and the cost of preparing dimensionally-stable dense fibrous products, combined with the cost of impregnating and heat setting can be very high.
[0007] U.S. Pat. No. 3,860,469 discloses another technique to produce inexpensive, dirt and bacterial growth resistant, and abrasion resistant surface covering materials with a textile fiber appearance in which flat or textured film-like skins are placed on top of a pile-like surface. The resultant floor covering products combine the qualities of carpet with the solidity of vinyl or rubber, but lack the textile quality and aesthetics of carpets.
[0008] Other attempts assemble a basically flat textile fabric over a sublayer of adhesive backed with various layers of sub-surface reinforcement. For example, International Patent Publication No. WO 99/19557 discloses a woven face fabric backed by reinforcing layers, and U.S. Pat. No. 5,965,232 discloses a decorative fabric attached to dimensionally-stabilizing or cushioning layers. The fabric is further surface-stabilized. Laminates having a flat fabric face, however, tend to delaminate or fray at the edges unless the fabric is thoroughly impregnated with adhesives. Unfortunately, impregnation with adhesives adversely affects the textile feel and cushioning quality of the laminate.
[0009] Because of these shortcomings, the need remains to provide a surface covering material that combines the desirable properties of both solid surface coverings and textile-type coverings into a single product. Suitable surface coverings would have at least some of the desired properties of surface stability, edge fray resistance, thermal stability, structural stability, dimensional stability, dirt resistance, bacteria resistance, soft textile hand, cushioning, and appearance extending over a full spectrum of tufted, knit, non-woven, woven, velour and velvet products.
SUMMARY OF THE INVENTION
[0010] Composite materials in accordance with the present invention utilize a fibrous face layer combined with an adhesive layer to form a multi-layer structure. In order to provide the desired level of surface stability, the surface fibers of the fibrous face layer form loops, and the loops descend into the adhesive layer and are anchored in the adhesive layer. The loops are densely spaced and shallow. Although any portion of the fibers or legs of the looped fibers in the face layer can be dispersed in the adhesive, a significant amount or substantially all of the descending fibers are dispersed in the adhesive layer, which is in contact with the face layer. A characteristic of this invention is that short and densely spaced fiber loops embedded in adhesive provide improved surface stability and retention of appearance under repeated loading. Another characteristic is the resistance to cut-edge fraying.
[0011] In order to maintain the desired aesthetic qualities of the composite material while achieving increased surface stability, the amount of penetration of the adhesive into the face layer is controlled. The adhesive layer is not allowed to penetrate into the top portion of the face layer. Therefore, the top of the face layer maintains its textile feel.
[0012] Various types of fibrous face layer constructions can be used depending upon the aesthetics desired and a balance of cost vs. performance Regardless of the type of fibrous layer used, all of the embodiments and arrangements illustrated herein have a relatively fine and dense surface texture and they can also be embossed to produce three-dimensional textured products. In addition, a three layer composite structure can be provided wherein a backing layer is also bonded or laminated to the adhesive layer such that the adhesive layer is disposed between the face layer and the backing layer. Added structural rigidity is provided by having the adhesive layer penetrate into the backing layer as well.
[0013] To prepare a composite material in accordance with the present invention, a fibrous face layer is arranged to have a relatively smooth top surface with a high density of fiber loop legs extending down through the thickness of the face layer to the bottom surface. An adhesive layer is brought into direct contact with the bottom surface of the face layer and embedded into the face layer to cause the adhesive to penetrate partially into the thickness of the face layer. In order to embed the adhesive layer in the face layer, pressure and heat can be applied. For a three layer laminate, the backing layer can be brought into direct contact with the adhesive layer before the adhesive layer is embedded into the face layer, allowing the adhesive layer to simultaneously penetrate into the backing layer. The adhesive layer may be pre-integrated onto the face layer or onto the backing layer before lamination. The adhesive layer may also contain non-adhesive reinforcing or blended components. The backing layer may also contain adhesive components, which may replace the need for a separate adhesive layer, if the adhesive is present in sufficient quantity to anchor and envelope the legs of the surface fiber loops descending into it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic representation of a three layer embodiment of the composite material in accordance with the present invention;
[0015] FIG. 2 is schematic representation of another three layer embodiment of the composite material;
[0016] FIG. 3 is a schematic representation of another three layer embodiment of the composite material;
[0017] FIG. 4 is a schematic representation of another three layer embodiment of the composite material;
[0018] FIG. 5 is a schematic representation of a non-woven fabric layer;
[0019] FIG. 6 is schematic representation of a needle punched non-woven fabric layer;
[0020] FIG. 7 is a schematic representation of a needle punched non-woven face layer embodiment of the present invention before lamination;
[0021] FIG. 8 is schematic representation of a needle punched non-woven face layer embodiment of the present invention after lamination;
[0022] FIG. 9 is a schematic representation of a non-woven fabric layer in contact with an adhesive layer;
[0023] FIG. 10 is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer;
[0024] FIG. 11 is a schematic representation of a non-woven fabric layer in combination with an adhesive layer and a backing layer;
[0025] FIG. 12 is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer and a backing layer before lamination;
[0026] FIG. 13 is a schematic representation of a non-woven fabric layer needle punched through an adhesive layer and a backing layer after lamination;
[0027] FIG. 14 is a schematic representation of a stitchbonded fabric layer before gathering;
[0028] FIG. 15 is a schematic representation of a stitchbonded fabric layer after gathering;
[0029] FIG. 16 is a schematic representation of a gathered stitchbonded fabric layer in combination with an adhesive layer and a backing layer before lamination;
[0030] FIG. 17 is a schematic representation of a gathered stitchbonded fabric layer in combination with an adhesive layer and a backing layer after lamination;
[0031] FIG. 18 is a schematic representation of a stitchbonded fabric layer having an adhesive layer before gathering;
[0032] FIG. 19 is a schematic representation of a stitchbonded fabric layer having an adhesive layer after gathering;
[0033] FIG. 20 is a schematic representation of a pattern bonded fabric layer before bonding and gathering;
[0034] FIG. 21 is a schematic representation of a pattern bonded fabric layer after bonding and before gathering;
[0035] FIG. 22 is a schematic representation of a gathered pattern bonded fabric layer in combination with an adhesive layer and a backing layer before lamination;
[0036] FIG. 23 is a schematic representation of a gathered pattern bonded fabric layer in combination with an adhesive layer and a backing layer after lamination;
[0037] FIG. 24 is a schematic representation of a pattern bonded fabric layer having an adhesive layer before bonding and gathering;
[0038] FIG. 25 is a schematic representation of a pattern bonded fabric layer having an adhesive layer after bonding and before gathering;
[0039] FIG. 26 is a schematic representation of a bonded and gathered pattern bonded fabric layer having an adhesive layer;
[0040] FIG. 27 is a schematic representation of a reversed pile knit fabric for use in the present invention;
[0041] FIG. 28 is a schematic representation of a reversed pile knit fabric having cut and raised free fiber ends for use in the present invention;
[0042] FIG. 29 is a schematic representation of a woven fabric for use in the present invention;
[0043] FIG. 30 is a schematic representation of a woven fabric having cut and raised free fiber ends for use in the present invention;
[0044] FIG. 31 is a schematic representation of an embodiment of an apparatus for stabilizing a woven or knit face layer during cutting and raising of fibers; and
[0045] FIG. 32 is a schematic representation of another embodiment of an apparatus for stabilizing a woven or knit face layer during cutting and raising of fibers.
DETAILED DESCRIPTION
[0046] Referring initially to FIGS. 1-4 , a fabric-faced composite material 10 in accordance with the present invention includes a face layer 12 containing a plurality of fibers. Suitable fabrics for face layer 12 include, but are not limited to, woven, non-woven, knit, stitchbonded or gathered structures. The face layer 12 includes top side or surface 16 and bottom side or surface 18 opposite top surface 16 , defining thickness 20 of face layer 12 between them. Top surface 16 is the surface or face of composite material 10 that is exposed when the laminate 10 is installed, for example on a substrate in a flooring application.
[0047] Composite material 10 also includes adhesive layer 22 disposed adjacent face layer 12 in direct contact with bottom surface 18 . Preferably, adhesive layer 22 is continuous or is composed of a single, smooth uninterrupted surface. Alternatively, adhesive layer 22 has a substantially constant thickness. Adhesive layer 22 can contain thermoplastic or thermosetting adhesives. Suitable materials for adhesive layer 22 include polyethylene, polypropylene, copolyester, copolyamide and combinations thereof. Suitable basis weights for adhesive layer 22 range from about 3 oz/yd 2 to about 14 oz/yd 2 , preferably about 4 oz/yd 2 to about 10 oz/yd 2 .
[0048] Adhesive layer 22 penetrates into face layer 12 distance 24 , which is sufficient to anchor face layer 12 and adhesive layer 22 together. In one embodiment, distance 24 ranges from about ¼ to about ¾ of thickness 20 of face layer 12 . Preferably, adhesive layer 22 does not penetrate completely through to top surface 16 of face layer 12 in order to preserve the soft, textile feel of composite material 10 . The depth of penetration of adhesive layer 22 into face layer 12 can be controlled by varying the construction of face layer 12 , the construction of adhesive layer 22 or the process conditions used to embed adhesive layer 22 into face layer 12 . In one embodiment, the viscosity of adhesive layer 22 is adjusted to limit the depth of penetration to within the lower ¾ of face layer 12 so that at least the upper ¼ of face layer 12 is free of adhesive. The average height 60 of the face layer above the average level of adhesive penetration varies between about 0.5 mm and about 2.0 mm, and the basis weight is in the range of about 100 grams/m 2 to about 500 grams/m 2 .
[0049] In general, the penetration of adhesive layer 22 into face layer 12 increases the amount or surface area of the adhesive layer that is in contact with the structure or fibers of the face layer 12 . Increasing the surface area contact between adhesive layer 22 and face layer 12 increases the strength of the bond between the two layers and the overall rigidity and strength of the resulting two layer laminate. Overall, this arrangement yields a composite material 10 with improved structural strength and rigidity and a pleasurable soft texture.
[0050] Although composite materials 10 in accordance with the present invention can contain just two layers, face layer 12 and adhesive layer 22 , additional layers may also be included. In three layer arrangements as illustrated in FIGS. 1-4 , composite material 10 also includes backing layer 26 in direct contact with adhesive layer 22 . Backing layer 26 is disposed such that adhesive layer 22 is disposed between backing layer 26 and face layer 12 . In order to provide increased structural rigidity, adhesive layer 22 also preferably penetrates or extends into backing layer 26 . Additional layers such as a gas permeable layer, bactericide layer or the like can also be added. As used herein, backing layer includes any layer, composite or laminate being attached to composite 10 . Composite 10 can also be embossed and simultaneously bonded and/or laminated to any backing layer.
[0051] In either the two layer or three layer embodiments of the current invention, the layers are laminated together by applying pressure and heat, preferably from top surface 16 , to cure or melt adhesive layer 22 and to control the depth of adhesive penetration. For thermosetting adhesives, adhesive layer 22 can be applied to bottom surface 18 of face layer 12 or to the top of backing layer 26 and the resultant structure can be cured under pressure with a hot tool at a temperature that cures adhesive layer 22 but leaves the fibers in face layer 12 and backing layer 26 intact. For thermoplastic adhesives, adhesive layer 22 is preferably pre-attached to bottom surface 18 of face layer 12 or the top face of backing layer 26 and preheated or pre-melted in-situ, for example by applying radiant heat, before all of the layers are laminated together under pressure. In one embodiment, adhesive layer 22 is preheated before applying pressure to adhesive layer 22 , face layer 12 or backing layer 26 .
[0052] A wide variety of materials can be used as backing layer 26 depending upon the desired thickness, strength and flexibility of three layer composite material 10 . In one embodiment, backing layer 26 is a pre-needled layer of higher-denier fibers of up to about 20 denier per filament or fiber and weighing at least about 10 oz/yd 2 . In another embodiment, backing layer 26 is a needled felt of reclaimed carpet fibers. In yet another embodiment, backing layer 26 is a used tufted carpet.
[0053] Although the fibers in face layer 12 at bottom surface 18 are spaced from backing layer 26 , these fibers can alternatively extend completely through adhesive layer 22 and be in contact with backing layer 26 . In addition, these fibers can extend completely through the adhesive layer 22 and into the backing layer 26 and even through the entire thickness of backing layer 26 . These arrangements can be achieved by controlling the composition of adhesive layer 22 and the process used to laminate the three layers together as discussed below. In addition, separate processes, for example needle punching, can be used to interlock the fibers of face layer 12 into adhesive layer 22 and backing layer 26 .
[0054] In general, the bottom surface 18 of fibrous face layer 12 includes a plurality of legs 19 dependent there from. Legs 19 are anchored into adhesive layer 22 in composite 10 and in some embodiments extend into backing layer 26 . Legs 19 include structures of face layer 12 such as free fiber ends of needle punched or spunlaced/hydraulically needled loops, FIG. 1 , undulating gathered loops of stitchbonded or pattern bonded fabrics, FIG. 2 , pile loops of knit fabrics, FIG. 3 , and cut and raised free fiber ends of knit and woven fabrics, FIG. 4 . The term “legs” or “legs formed from loops” as used herein includes all of these structures or portions thereof, and also includes any remaining fiber portions of the loops that have been cut to form piles. Processes such as laminating using pressure and heat and needle punching are used to anchor legs 19 into adhesive layer 22 .
[0055] In one embodiment in accordance with the present invention as shown in FIGS. 5-8 , composite material 10 includes needled, non-woven face layer 12 containing a plurality of fibers 14 . In one embodiment, non-woven face layer 12 contains a web of staple fibers. Suitable staple fibers range from about 0.5 denier to about 5 denier per filament or fiber and have a length ranging from about 0.5 inches to about 3 inches, forming a non-woven web having a weight ranging from about 3 oz/yd 2 to about 14 oz/yd 2 .
[0056] Although fibers 14 are initially arranged in a generally planar pattern in face layer 12 as illustrated in FIG. 5 , a portion of fibers 14 are needle punched or hydraulically needled (spunlaced) toward bottom surface 18 as illustrated in FIG. 6 . When mechanical needle punching is used, the needling density is at least over 500 penetrations per square inch (ppsi) and preferably over 1,000 ppsi. The web of fibers 14 is needled from top surface 16 with a relatively large number of needle penetrations per unit area. Generally, the needle punch density is from about 250 needles/in 2 to about 2000 needles/in 2 . In one embodiment, web 14 has a needle punch density of at least about 250 needles/in 2 . Alternatively, the needle punch density is at least about 500 needles/in 2 . Preferably, the needle punch density is at least 1000 needles/in 2 .
[0057] The product of FIG. 5 can also be formed using hydraulic needling (spunlacing). Preferably, the needled web consists of shorter fibers, up to about 2 inches long, preferably less than about 1 inch and more preferably shorter fibers, including pulps. Also, preferably the needling jets are relatively not dense, e.g., less than 50 penetrations/inch. The needling is performed substantially or totally from the top, and the needling energy is relatively high, e.g., at least 20 HP·HR/lb.
[0058] In this embodiment, face layer 12 is densified and acquires a relatively smooth top surface or upper face 16 containing a plurality of loops 32 facing downward. Each loop 32 contains free fiber ends or legs 34 that descend through face layer 12 and terminate at bottom surface 18 . In order to form a three layer configuration of this embodiment, adhesive layer 22 is placed in direct contact with bottom side 18 and backing layer 26 such that adhesive layer 22 is disposed between face layer 12 and backing layer 26 as is shown in FIG. 7 . After activation of adhesive layer 22 as shown in FIG. 8 , adhesive layer 22 penetrates partially into face layer 12 and backing layer 26 , laminating all three layers together. Needled fibers 14 are anchored in adhesive layer 22 at legs 34 of loops 32 . The upper strata or layers of face layer 12 remain free of adhesive from adhesive layer 22 .
[0059] Preferably, in this embodiment, the selected non-woven face layer 12 , FIG. 5 , is needle punched or spunlaced (hydraulically needled) to produce a plurality of free fiber ends 34 at bottom surface 18 , FIG. 6 . Continuous adhesive layer 22 is then placed in direct contact with bottom surface 18 , FIG. 7 , and adhesive layer 22 is embedded into face layer 12 a sufficient distance to anchor face layer 12 in adhesive layer 22 . In order to embed adhesive layer 22 into face layer 12 , adhesive layer 22 is heat activated. Pressure may also be applied to top surface 16 of face layer 12 . A variety of methods can be used to apply heat and pressure to top surface 16 such as contacting top surface 16 with one or more heated pressure plates (not shown). Adhesive layer 22 may also be preheated as for example with radiant heat before placing face layer 12 upon it.
[0060] Referring to FIGS. 9 and 10 , face layer 12 is brought into direct contact with adhesive layer 22 before face layer is needle punched, FIG. 9 . Then, face layer 12 is needle punched so that free fiber ends 34 penetrate into and in some cases completely through adhesive layer 22 . Spunlacing or hydraulic needling is not applicable with the embodiment shown in FIGS. 9 and 10 . In this embodiment, adhesive layer 22 may constitute a low-melt thermoplastic sheet or layer, e.g. polyethylene, polypropylene, low-melt copolyester or copolyamide. This sheet or layer can be in the form of a film or fabric, for example a non-woven fabric, or a layer of low-melt fibers. After the fibers are needle punched into adhesive layer 22 , adhesive layer 22 is heat activated and laminated to face layer 12 using pressure as described above.
[0061] Referring to FIGS. 11-13 , in addition to bringing adhesive layer 22 into contact with face layer 12 prior to needle punching, backing layer 26 can also be brought into contact with adhesive layer 22 before needle punching. In this three layer embodiment, backing layer 26 is placed in direct contact with adhesive layer 22 such that adhesive layer 22 is disposed between backing layer 26 and face layer 12 ( FIG. 11 ). Then, face layer 12 is needle punched resulting in fiber ends 34 that extend completely through adhesive layer 22 and into backing layer 26 ( FIG. 12 ). The composite material 10 is then finished by heat activating adhesive layer 22 in-situ with or without substantial applied pressure ( FIG. 13 ). In this embodiment, backing layer 26 is preferably a heavier and more resilient structure than face layer 12 so that backing layer 26 does not collapse as a result of the dense needling action.
[0062] Referring to FIGS. 14-17 , another embodiment of the composite material 10 in accordance with the present invention is illustrated wherein face layer 12 is an undulated, gathered or folded structure with the plurality of fibers disposed in a gathered layer forming a plurality of downwardly facing loops 40 disposed at top surface 16 and descending from top surface 16 to bottom surface 18 and a plurality of upwardly facing loops 42 disposed at bottom surface 18 and ascending through face layer 12 .
[0063] Suitable gathered structures include creped webs, microfolded webs, non-wovens, wovens, and knits. The structures also include webs, non-wovens, knits and wovens that are stitched with shrinkable yarns and post-shrunk to form folded structures. Suitable shrinkable yarns include stretched elastic yarns, partially oriented yarns, and flat, fully oriented yarns heated near the melting points of the yarns to cause the yarns to shrink. Polyolefin yarns are also suitable for shrinking 5-20° C. below their melting points. Face layer 12 can also include a plurality of secondary non-shrinking yarns (not shown) in contact with the stitching substrate. These secondary yarns can be stitched-in or laid-in yarns.
[0064] As illustrated in FIG. 15 , face layer 12 is a stitchbonded layer that includes a buckled stitching substrate 44 containing the plurality of fibers and a substantially planar network of shrinkable yarns 46 stitched to the stitching substrate. To produce a relatively smooth surface, the stitching frequency is relatively high in both directions (gauge and CPI), between about 6 stitches per inch and about 30 stitches per inch, preferably between about 10 stitches per inch and about 30 stitches per inch. In addition, face layer 12 , before being folded or gathered, has a fabric basis weight ranging from about 25 gm/m 2 to about 150 gm/m 2 . After folding and gathering, face layer has a fabric basis weight ranging from about 100 gm/m 2 to about 600 gm/m 2 and a folded frequency ranging from about 12 folds per inch to about 60 folds per inch. In addition, the thickness of face layer 12 is from about 0.5 mm to about 2 mm thick after folding.
[0065] In an alternative embodiment as is illustrated in FIGS. 18-19 , adhesive layer 22 can be integrated within the stitch-bonded structure of face layer 12 . In this embodiment, adhesive layer 22 can be a shrinkable layer that assists in creating the gathered structure of face layer 12 . Suitable adhesive layers include polyolefin films that shrink at about 130° C. to about 160° C. by a factor of about 1.3 to about 2.2 without melting. Suitable gathering frequencies and fabric weights for this arrangement are the same as for the embodiment illustrated in FIGS. 14 and 15 . Suitable stitch-bonded structures of face layer 12 are disclosed in common owned, co pending patent application entitled “Stitch-bonded and Gathered Composites and Methods for Making Same,” by the same inventor as the present invention and filed on the same day as this patent application.
[0066] In order to make the composite material 10 of the embodiment illustrated in FIGS. 14-17 , stitching substrate 44 containing the plurality of fibers is selected and stitchbonded using shrinkable yarn 46 in accordance with the desired fabric weight and gathered density, FIG. 14 . Shrinkable yarn 46 is then shrunk to produce the gathered fabric structure, FIG. 15 . Adhesive layer 22 is then brought into contact with bottom surface 18 of gathered face layer 12 and embedded into face layer 12 to form a two-layer laminate. Adhesive layer 22 is embedded into face layer 12 by applying heat and pressure. Although adhesive layer 22 is preferably in direct contact with the technical bottom surface 18 of face layer 12 , adhesive layer 22 may alternatively be placed in direct contact with the technical top surface 16 of face layer 12 . If a three layer laminate is being made, backing layer 26 is brought into contact with adhesive layer 22 prior to application of the heat and pressure so that adhesive layer 22 also penetrates into backing layer 26 , FIGS. 16 and 17 .
[0067] In another embodiment as illustrated in FIGS. 20-23 , face layer 12 is a thin and dense gathered, pattern bonded layer containing face layer substrate 50 containing a plurality of fibers and shrinkable sublayer 52 attached or bonded to face layer substrate 50 with a spaced pattern of a plurality of discrete bonds 54 , FIG. 21 , placed at frequencies similar to the stitch frequencies of the embodiments illustrated in FIGS. 14-17 . Heated pattern bonding tool 55 is used to produce bonds 54 . Face layer 12 is a fibrous web or fabric having a total buckled thickness of from about 0.5 mm to about 2 mm. Shrinkable sublayer 52 is preferably relatively open to allow the penetration of the thermoplastic or thermoset adhesive from adhesive layer 22 into face layer 12 . As with other embodiments of the present invention, thermoset or thermoplastic adhesives may benefit from the pre-application of adhesive layer 22 to one or both mating surfaces. Thermoplastic lamination may also benefit from preheating to accelerate the lamination process.
[0068] As shown in FIGS. 24-26 , adhesive layer 22 can be integrated into the structure of face layer 12 before substrate 50 is bonded to shrinkable sublayer 52 . In order to be integrated into face layer 12 , adhesive layer 22 is placed in direct contact with shrinkable sublayer 52 such that shrinkable layer 52 is disposed between adhesive layer 22 and substrate 50 , FIG. 24 . In this embodiment, adhesive layer 22 is preferably a shrinkable layer. The three layers are then bonded together with the discrete bonds 54 , FIG. 25 . Following bonding, shrinkable sublayer 52 and, if applicable, adhesive layer 22 are shrunk to produce gathered face layer 12 , FIG. 26 .
[0069] In order to make the composite material in accordance with the arrangements illustrated in FIGS. 20-23 , fibrous substrate 50 is selected and shrinkable substrate 52 placed in contact with fibrous substrate 50 , FIG. 20 . Fibrous substrate 50 and shrinkable substrate 52 are then bonded together in a pattern similar in frequency to those depicted in FIGS. 14-19 in accordance with the desired fabric weight and gathered density. Suitable methods for pattern bonding these layers together include applying heated pattern plate 55 containing the desired pattern to top surface 56 of substrate 50 , FIG. 21 . Shrinkable substrate 52 is then shrunk to produce the gathered face layer structure, FIG. 22 . Adhesive layer 22 is then brought into contact with bottom surface 18 and embedded into face layer 12 for example by applying heat and pressure. If a three layer laminated is being made, backing 26 is brought into contact with adhesive layer 22 prior to application of the heat and pressure so that adhesive layer 22 also penetrates into backing layer 26 , FIG. 23 .
[0070] In another embodiment in accordance with the present invention as illustrated in FIG. 3 , face layer 12 is a reversed knit or woven pile fabric layer. Suitable reversed knit or woven pile fabrics include those used to prepare velours or velvets. Pile side 58 of face layer 12 is sufficiently long to provide for adequate embedding of adhesive layer 22 into face layer 12 to stabilize face layer 12 . Suitable fabrics have basis weights that range from about 4 oz/yd 2 to about 16 oz/yd 2 , preferably about 6 oz/yd 2 to about 12 oz/yd 2 (about 200 gm/m 2 to about 400 gm/m 2 ). As in the case of surface layers 12 in accordance with the present invention, fabric face layer 12 provides a durable and decorative surface that utilizes finer and softer fibers that can be applied over backing layer 26 containing lower-cost, stiffer fibers to provide cushion, body, and dimensional stability.
[0071] In order to make composite material 10 in accordance the embodiment of FIG. 3 , knit or woven pile fabric face layer 12 is selected and adhesive layer 22 is brought into direct contact with bottom surface 18 of face layer 12 . Adhesive layer 22 is then embedded into fabric face layer 12 , for example by the application of heat and pressure. If a three layer arrangement is desired, backing layer 26 is brought into direct contact with adhesive layer 22 before adhesive layer 22 is embedded into fabric face layer 12 so that adhesive layer 22 will also embed or penetrate into backing layer 26 .
[0072] Referring to FIGS. 27 and 28 , when face layer 12 is a knit fabric, face layer 12 contains a plurality of overlaps 60 on top surface 16 and a plurality of underlaps 61 on bottom surface 18 . In order to provide for stronger bonding between knit fabric face layer 12 and adhesive layer 22 , underlaps 61 can be cut, sanded, brushed or sheared at bottom surface 18 to produce a plurality of cut and raised fibers 62 . When laminated to adhesive layer 22 , adhesive layer 22 will embed into fabric face layer 12 throughout the area of cut and raised fibers 62 . This embodiment utilizes many different kinds of knits. Suitable knits contain underlap loops 61 that can be cut and raised on back surface 18 without affecting the texture of top surface 16 .
[0073] Referring to FIGS. 29 and 30 , face layer 12 contains a woven fabric having a plurality of warp yarns 64 and a plurality of weft yarns 66 . Weft yarns 66 have been cut, sanded, brushed or sheared on one surface of woven fabric face layer 12 in a manner that leaves yarn overlaps 68 of interconnecting warp yarns 64 intact and produces a plurality of cut and raised fibers 62 at bottom surface 18 .
[0074] In order to make a composite material in accordance with the embodiments illustrated in FIGS. 27-30 , a knit or woven face layer 12 is selected and the pile loop side for the knit fabric or one side of the woven fabric is sanded or cut to produce cut and raised fibers 62 . Adhesive layer 22 is then brought into direct contact with cut and raised fibers 62 and embedded into face layer 12 . Adhesive layer 22 can be embedded by the application of pressure and heat. If a three layer embodiment is desired, backing layer 26 is brought into contact with adhesive layer 22 before adhesive layer 22 is embedded into face layer 12 so that adhesive layer 22 will also penetrate into backing layer 26 .
[0075] Since knit or woven face layer 12 is being cut or abraded, which weakens the structural integrity of the fabric, face layer 12 can be stabilized before being cut or sanded to assist in preserving the knit or woven structure during cutting or shearing. Stabilization or immobilization can be achieved by attaching a stabilizing sheet or a temporary layer of adhesive to top surface 16 prior to cutting, sanding or abrading bottom surface 18 . Following cutting, lamination of face layer 12 to the other layers can be performed with the face stabilizer left in place or removed.
[0076] In another embodiment of stabilizing face layer 12 as illustrated in FIGS. 31 and 32 , face layer 12 can be stabilized on high friction roller 70 . As illustrated, a continuous feed of face layer 12 from face layer roll 72 is introduced onto high friction roller 70 . Face layer 12 is then exposed to sanding roller 74 , brushing roller 76 or napping roller 78 producing cut and raised fibers 62 while stabilizing top surface 16 . Backing layer 26 and adhesive layer 22 are brought into contact with each other and heated and then laminated to face layer 12 while face layer 12 is still immobilized on high friction roller 70 . Optionally, roller 70 may be heated. The finished composite material is then collected on take-up roller 80 . Adhesive layer 22 can be introduced as a continuous sheet, FIG. 31 , applied to backing layer 26 using a spray heads 82 , FIG. 32 , or applied to backing layer 26 as a foam 84 that is then doctor knifed 86 to the desired thickness, FIG. 32 .
EXAMPLES
Example 1
[0077] A blend of 80% 1.5 denier 1.5 inch polyester fibers and 20% 1.5 denier 1.5 inch polypropylene fibers is carded and lapped into a structure weighing approximately 8 oz/sq.yd. This face layer is then needled from one side only with 1,500 penetrations/sq.in. forming a dense surface and a very fur-like backface with many free ends and loops, as shown in FIG. 6 .
[0078] A second blend of 80% 15 denier, 1.5 inch cut polyester and 20% 1.5 denier 1.5 cut polypropylene fiber is carded and lapped into a 24 oz/sq.yd batt and needled with 300 penetrations per square inch from one face to form the backing layer.
[0079] A dual layer of 0.05 inch thick polyethylene utility films is placed between the face layer and the backing layer, with the needled sides of the face layer and the backing on the outside and pressed with a plate heated to about 200 degrees C. placed against the face layer, at 1000 psi for 3 seconds. The plate facing the backing is at room temperature. The product is solidly laminated with all free fiber ends embedded in the molten polyethylene. Adhesive penetrates the two layers, but leaves a thickness of face layer approximately 1 mm thick free of adhesive. Delamination cannot be achieved without damage to the face or backing layers. The surface is smooth, durable and traffic-wear resistant with a textile feel and improved edge-fraying resistance.
Example 2
[0080] The face layer of Example 1 is needled into the adhesive layer before laminating onto the backing layer. The stability of the surface is superior to Example 1. Delamination without destroying the layers is even more difficult. The surface is fibrous, smooth, free of adhesive and traffic-wear and edge-fraying resistant. The fibrous height above the adhesive penetration is approximately 0.9 mm.
Example 3
[0081] The needled face layer of Examples 1 and 2 is needled directly through the dual adhesive layer and into the backing ( FIG. 12 ) before the hot pressing process. The product has a textile feel and excellent durability and is delamination resistant.
Example 4
[0082] A non-woven fabric containing commercial polyester Sontara® spunlaced Style 8034 (20 g/m 2 ), sold by E. I. DuPont de Nemours, is stitched with P.O.Y. polyester yarn (155 denier/34 filament) using a stitch pattern of 1,0/3,4 at 14 gauge and 12 cpi. After stitching the product is subjected to 190 degrees C. for 30 seconds within a tentering frame, allowing it to shrink by a ratio of 1.7/1 both in the machine and cross directions. It forms a thin and dense undulated folded fabric structure as shown in FIG. 15 . This fabric is placed over the dual layers of adhesive and backing of Example 1 and laminated as described in Example 1. The composite is very stable and traffic-wear resistant and has a textile feel with improved resistance to edge-fraying. Loop density is approximately 22/inch in both directions and loop height above the adhesive penetration is approximately about 1 mm.
Example 5
[0083] The stitching bonding step for the face layer of Example 4 is repeated with an additional layer of 5.5 mil thick polyethylene adhesive film placed over the Sontara® nonwoven. After shrinking by a ratio of 1.6/1 in both directions by subjecting it to 150 degrees C. for 30 seconds within a frame, a buckled face layer containing an added layer of polyethylene on its technical back is produced ( FIG. 19 ). The composite is laminated to the backing of Example 1 under the same conditions with the same excellent results.
Example 6
[0084] In this example, a folded layer produced by shrinking a dual shrinkable/non-shrinkable laminate is illustrated. A buckled face layer is constructed by intermittently “tacking” a layer of Style 8003 spunlaced non-woven polyester Sontara® (1.9 oz/yd 2 or about 50 gm/m 2 ) to a shrinkable sublayer consisting of a carded web of polypropylene staple weighing 30 gm/m 2 . The bonding pattern consists of elevated lines 0.5 mm thick extending across every 2 mm. Tacking is preformed using a heated patterned plate that is heated to 200 degrees C. and placed on the polyester side using 1000 psi for about 2 seconds. The polypropylene side rests against a room temperature steel plate.
[0085] Upon heating the composite to 150 degrees C., the polypropylene layer shrinks to approximately 67% of its initial length, producing an undulated structure ( FIG. 22 ). This undulated face layer is placed over a dual layer of 5.5 mil thick polyethylene over the same backing used in Examples 1 and pressed in the same manner to produce a very coherent laminate with a textile feel, and improved edge-fraying resistance.
Example 7
[0086] In this example, a folded layer containing a shrinkable adhesive layer, produced by pattern bonding and shrinking is illustrated. The process of Example 6 is repeated with a layer of polyethylene adhesive placed under the spunlaced sheet before tacking to the shrinkable backing ( FIG. 24 ). The assembly is pretacked and shrunk at 150 degrees C. to produce the composite face and adhesive layer.
[0087] Subjecting this composite face/adhesive layer to the same lamination process in Example 6 over the same backing resulted in excellent adhesion, surface stability and edge fraying resistance.
Example 8
[0088] In this example, a face layer consisting of commercial velour knit is applied with the pile face down against the adhesive layer. A commercial knit nylon velour fabric that was 1.1 mm thick and weighed 12.8 oz/yd 2 was laminated to the backing described above using the 5.5 mil polyethylene film described above, by pressing from one face only with a platen at 200 degrees C. for 1 second with the pile facing the adhesive film. Fabric thickness above the adhesive penetration line was approximately 0.9 mm. Excellent adhesion, surface stability and textile hand resulted. The product was highly resistant to edge fraying.
Example 8A (Prior Art)
[0089] The velour knit was laminated with the pile face up. Adhesion and edge fraying resistance were not achieved until pressure and time were increased over 3 seconds with some adhesive rising near the top of the face layer. This example is outside the scope of the present invention.
Example 9 (Prior Art)
[0090] This example illustrates how a commercial cotton denim fabric that does not respond well to thermoplastic lamination can be converted to produce high-performance composite in accordance with the present invention.
[0091] A commercial woven cotton fabric weighing 12.8 oz/yd 2 was laminated to the backing described above using the dual polyethylene films described above in a heated press. Top surface temperature was varied between 180 and 230 degrees C. Pressure at each step was varied between 150 and 10,000 psi, and the pressing time at each temperature combination was between about 0.5 and about 3 seconds. Lamination without relative ease of delamination was not achieved without penetrating the woven with polyethylene adhesive in spots or over the entire surface area. Surface stability versus traffic wear resistance also could not be achieved unless the adhesive resin rose to the top of the face layer. The cut edges of this composite frayed easily. This example is also outside the scope of the present invention.
Example 10
[0092] The cotton woven mentioned in Example 9 was prestabilized by prelaminating onto commercial pressure sensitive Duct Tape. The stabilized product was held on a table top and hand sanded on the opposing face using a pad of 150 grit sandpaper until a uniform shade change indicated that practically all of the originally exposed yarns underneath were cut, and the face fabric assumed a highly open velvet-like surface. The fabric was then laminated onto the backing used in the above examples using a single layer of polyethylene, and pressing at 10,000 psi with the top plate heated to 180 degrees C. for 3 seconds. The pressure sensitive tape was removed, with minimal tape adhesive contamination remaining in a few spots on the surface. Excellent lamination, without a tendency to fray at cut edges and with an adhesive-free textile surface was achieved. The product had excellent surface stability versus traffic-wear resistance. The cut edges were highly resistant to fraying.
[0093] Although specific forms of the invention have been selected for illustration in the drawings and the preceding description is drawn in specific terms for the purpose of describing these forms of the invention fully and amply for one of average skill in the pertinent art, it should be understood that various substitutions and modifications which bring about substantially equivalent or superior results and/or performance are deemed to be within the scope and spirit of the following claims.
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The present invention is directed to multiple layer composites suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from and the benefit of Korean Patent Application No. 10-2010-0034008, filed on Apr. 13, 2010, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND
1. Technical Field
The present invention relates to a wiper blade mounted on a wiper device of a vehicle to wipe a glass surface, and more specifically, to a wiper blade with heating elements capable of optimally keeping a condition of the wiper blade in order to wipe a glass surface even during winter when the external temperature is low by automatically turning-on or turning-off the heating elements embedded in a wiper blade and a method for controlling a wiper blade.
2. Description of the Related Art
As shown in FIG. 1 , a wiper device according to the related art includes a wiper arm 9 that rotates left and right by a motor (not shown) disposed in a vehicle and a wiper blade 1 mounted on the wiper arm 9 to move together. The wiper blade 1 includes a rubber strip 2 that wipes a glass surface while moving over the glass surface (not shown) closely.
The wiper blade 1 is coupled with the wiper arm 9 to rotate at a predetermined angle according to the driving of the motor. To this end, the wiper blade 1 according to the related art includes first link members 3 coupled with the wiper arm 9 , a plurality of second link members 5 that are coupled with the first link members 3 to uniformly transfer the pressure of the wiper arm 9 , and a plurality of third link members 7 that are coupled with the second link members 5 to connect the rubber strip 2 .
In this configuration, the second link members 5 adjacent to the rubber strip 2 and the ends of the third link members 7 are provided with clips 5 a and 7 a , respectively, to couple the rubber strip 2 by being inserted into a rail groove formed in the rubber strip 2 .
As described above, the wiper blade 1 according to the related art is formed to flexibly bend the rubber strip 2 along the glass surface of a vehicle by rotatably coupling the plurality of link members 3 , 5 , and 7 at a predetermined angle to each other.
However, the rubber strip 2 of the wiper blade contracts during winter when the temperature is low, such that it becomes rigidly hardened. Therefore, when the rubber strip 2 is not flexible, the rubber strip 2 does not completely adhere to the glass surface of a vehicle. In particular, both ends of the rubber strip 2 come off the glass surface, such that there is a problem in that the contact area with the glass surface becomes small, etc.
A wipe blade to optimally wipe the glass surface even during the winter when external temperature is low by embedding the heating elements in the wiper blade has been developed. However, the wiper blade with the heating elements according to the related art cannot appropriately control the heating elements and can waste power by supplying power to the heating elements for a longer time than needed, since a driver determines whether the generation of heat of the wiper blade is needed to supply power to the heating elements by inserting a power connection part connected to the heating elements into a cigarette outlet.
BRIEF SUMMARY
In one embodiment, a wiper blade is provided with heating elements capable of appropriately controlling the heating elements and saving energy by automatically supplying power to the heating elements while considering a driving state of a vehicle, external temperature, etc., and a method for controlling the wiper blade.
According to another embodiment of the present invention, there is provided a method for controlling a wiper blade with heating elements embedded therein and coupled to a wiper arm of a vehicle to wipe a glass surface while moving together with the wiper arm, including: detecting the operation or not of an engine of a vehicle; detecting the external temperature outside of the vehicle; and automatically supplying power to the heating elements based on the detected information on the operation of the engine and the temperature information.
According to one embodiment, the operation or not of the engine is detected through the fluctuation in voltage of a battery that is mounted in an engine compartment together with the engine.
According to one embodiment, the fluctuation in voltage of the battery is sensed by a voltage sensing sensor and is transferred to a microcomputer through an external input port in a controller.
According to one embodiment, the temperature information outside the vehicle detected by a temperature sensor is transferred to the microcomputer through the external input port in the controller.
According to one embodiment, the information on the operation of the engine and the temperature information are transferred to the microcomputer in the controller and the microcomputer determines whether a switch is turned-on through the operation information and the temperature information.
According to one embodiment, the switch is automatically turned-off by sensing when a predetermined time elapses after the operation of the heating element or when the operation of the engine stops to end the operation of the heating element.
According to one embodiment, the operation state of the heating element is displayed through a display device recognizably installed on the outside of the wiper blade.
According to another embodiment of the present invention, there is provided a wiper blade including a rubber strip that contacts a glass surface to wipe the glass surface, a frame that is coupled with the rubber strip, and an adaptor that is coupled with the frame to connect to a wiper arm of a vehicle and wiping the glass surface while moving together with the wiper arm of the vehicle, the wiper blade comprising: a heating element that is embedded in the wiper blade and whose generation of heat is controlled by the control method.
In one embodiment, the heating element is supplied with power from a battery installed in an engine compartment of the vehicle.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front view of a wiper blade according to the related art;
FIG. 2 is a conceptual diagram of a wiper blade with heating elements according to one embodiment of the present invention; and
FIG. 3 is a block diagram for explaining a method of controlling the wiper blade with the heating elements according to one embodiment of the present invention.
DETAILED DESCRIPTION
Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
As shown in FIG. 2 , a wiper blade with heating elements according to an exemplary embodiment of the present invention includes a strip 51 made of a rubber material to wipe a glass surface while closely moving over a glass surface, a frame (not shown) coupled with the rubber strip 51 , and an adaptor 55 that is disposed at the center of the frame to be able to connect the wiper blade to a wiper arm (not shown).
Further, according to the exemplary embodiment of the present invention, spoilers 53 may each be coupled left and right on the frame of the wiper blade based on the adaptor 55 , thereby making it possible to prevent the wiper blade from coming off the glass surface during the driving of a vehicle.
Although the shape and configuration of the wiper blade 50 is described above, the method for controlling the wiper blade according to the present invention is not limited by the type of wiper blade and thus, may be applied to the wiper blade according to the related art as shown in FIG. 1 .
As the rubber strip 51 , one similar to the rubber strip 2 of the related art shown in FIG. 1 may be used. The frame presses the rubber strip 51 to the glass surface with a predetermined elastic force so that the rubber strip 51 is closely attached to the glass surface of a vehicle. To this end, the frame has a shape of a long bent metal plate.
The left and right spoilers 53 may be made of rubber or flexible plastic materials and have an inclined surface, thereby preventing the wiper blade from coming off the glass surface even when a vehicle is driven at high speed.
As described above, the adaptor 55 of the wiper blade is installed approximately at the center in a longitudinal direction of the frame to couple the wiper blade to the wiper arm of a vehicle. With respect to the type of wiper arm connected to the adaptor 55 , there are various types, such as a hook type, a side pin type, etc. The adaptor 55 may be formed to connect to a specific type of wiper arm or various types of wiper arms, if necessary.
The heating element to heat the wiper blade is attached to the frame having the metal plate shape. Preferably, the heating element is a heating element having a film shape that can be used in the temperature range of approximately 30 to 40°, for example, a film heater.
The wiper blade 50 with the heating element may be electrically connected to a battery 13 of a vehicle through a controller (control unit) 30 and may be modified to receive power from a power supply unit such as a dedicated battery, etc., if necessary, in addition to a battery of a vehicle.
Meanwhile, whether power is supplied to the heating element may be recognized from the outside by installing a display unit such as an LED (not shown) at the outside of the wiper blade 50 , for example, the outside of the end of the spoiler 53 or the adaptor 55 , etc.
In addition, according to one embodiment of the present invention, the heating element may be manually turned-on or turned-off by the driver if necessary by including a passive switch in the controller 30 .
Hereinafter, the method for controlling a wiper blade with the heating elements according to various embodiments of the present invention will be described with reference to FIG. 3 . According to one embodiment of the present invention, the heating element installed in the wiper blade is configured to be automatically turned-on or turned-off while considering the operation or not of an engine and the temperature outside a vehicle.
When the driver starts an engine 11 , the voltage of the battery 13 that is disposed in an engine room or engine compartment 10 together with the engine 11 is instantly increased to about 1 to 4V above normal. In other words, although each vehicle has differences, the voltage of the battery 13 that is generally maintained at 12V is increased at the time of starting the engine.
When a voltage sensing sensor 23 senses the voltage increasing phenomenon, the information is transferred a microcomputer 33 through an external input port 31 in the control unit (controller) 30 .
Similar to the voltage information, the information regarding the temperature outside a vehicle detected by a temperature sensor 25 installed at a predetermined position of a vehicle is transferred to the microcomputer 33 through the external input port 31 in the control unit (controller) 30 .
The microcomputer 33 determines a predetermined condition, for example, a condition where temperature becomes 0° C. or less while the engine is operated, etc., through the temperature information and the voltage information. When the condition is satisfied, a heater (heating element) 41 is operated by turning-on a switch 35 .
The turning-off the operation of the heater (heating element) 41 may be performed by a method for automatically turning-off the switch when a predetermined time elapses after the operation, a method for automatically turning-off the switch by sensing when the operation of the engine stops, etc.
As described above, when the recognizable display device, for example, the LED 43 is installed outside the wiper blade 50 , the LED is operated by the turning-on or turning-off of the heater 41 .
According to various embodiments of the present invention, the wiper blade with the heating elements capable of automatically supplying power to the heating elements while considering the driving state of a vehicle, the external temperature, etc., and the method for controlling the wiper blade are provided.
With the wiper blade with the heating elements and the method for controlling the wiper blade, it can automatically control appropriately the heating elements if necessary while saving energy.
As described above, although the method for controlling the wiper blade with the heating elements according to exemplary embodiments of the present invention is described with reference to the accompanying drawings, the present invention is not limited to the above exemplary embodiments and drawings and thus, may be variously modified and changed by those skilled in the art to which the present invention pertains.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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Disclosed is a method for controlling a wiper blade with heating elements embedded therein and coupled to a wiper arm of a vehicle to wipe a glass surface while moving together with the wiper arm. The method includes: detecting the operation or not of an engine of a vehicle; detecting the external temperature outside of the vehicle; and automatically supplying power to the heating elements based on the detected information on the operation of the engine and the temperature information. A wiper blade with heating elements capable of optimally maintaining a condition of the wiper blade even when the external temperature is low is also provided.
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FIELD OF THE INVENTION
[0001] The present invention relates to a device for lowering, alternatively later retrieval, of a pipeline end provided with a connecting part designed for “horizontal” mating with and connection to a connecting part on the seabed, The present invention relates particularly to a device for lowering, alternatively later retrieval of a second pipeline end where a first pipeline end is already arranged on the seabed.
TECHNICAL BACKGROUND OF THE INVENTION
[0002] When a pipeline, for transportation of for instance oil and gas, is laid out on the seabed and is to be connected to a fixed coupling point, it has been common practice to use a tie-in and connecting tool, which is lowered from the sea surface. The tool is put down over the coupling point and a wire line is brought out from the tool and secured to the pipeline end that is to be tied in before the connecting operation can take place. When the pipeline ends, which have a respective flange, are brought against each other, the connecting operation can take place by means of a clamp connector. The clamp connector has internal beveled surfaces, which cooperate with external beveled surfaces on the pipeline flanges. When the clamp connector is activated, the respective beveled surface effects that the pipeline ends are pulled axially towards each other by substantial force and connecting engagement takes place.
[0003] There exist two principles for the connecting devices, either vertical or horizontal. The term horizontal means that the connection device is substantially horizontal related to the seabed. The term vertical means that the connection device is substantially vertical in relation to the seabed.
[0004] For a horizontal connecting device the connecting point projects horizontally out from the structure, and the connecting parts are mated in a substantially horizontal direction. In the North Sea this solution almost has market control. Other places, like the Gulf of Mexico for example, the vertical solution is the most common one.
[0005] There are in principle three (or actually two) different forms for external connections to a structure as described below:
Direct connection between two structures: Here, a rigid pipe having a mobile connecting part at each end, will normally be used. This will usually be termed a jumper. The jumper is manufactured based on measuring the relative position of the two connecting points. Connection between the end of a pipeline (rigid pipe) and a structure: It is almost impossible (or at least very difficult) to connect a rigid pipeline directly to a structure preinstalled on the seabed. Thus, an intermediate piece of pipe, frequently termed a “spool”, is provided between the pipeline and the structure. In order to be able to connect the spool to the pipeline, the pipeline will be welded directly to a small structure including a connecting point. A spool is in principle similar to the jumper described above. Direct connection of a flexible pipeline or umbilical to a structure: In some cases, it is chosen to use so called flexible pipes instead of rigid steel pipes. Such pipes can be compared to a big garden hose. Then it is neither necessary to have a spool or jumper between the end of the pipe and the structure, nor to make precise measurements of the position on the connecting point on the structure.
[0009] The application is related to connection of flexible pipelines.
[0010] A connecting system of this type usually comprises an inboard connecting part and a landing structure that is lowered to the seabed beforehand, and an outboard connecting part that is connected to a pipeline that is lowered to the seabed for mating with and connection to the inboard connecting part at the seabed. Usually, the inboard connecting part is lowered to the seabed before lowering of the outboard connecting part and the pipeline end, but it is also possible to lower the outboard connecting part with the pipeline end to the seabed before the inboard connecting part is installed at the seabed.
[0011] The invention can be used to deploy both a first and a second end of a flexible pipeline. The problems to be addressed can be somewhat different when the first end is to be laid from a surface vessel and down to the seabed compared to deployment of the second end.
[0012] When lowering the first pipeline end, the remaining part of the pipeline is at the sea level, the lifting device of the outboard connecting part will therefore carry only the load of the outboard connecting part and a part of the pipeline that is lowered to the seabed.
[0013] When the second end of a pipeline is lowered to the seabed, the remaining part of the pipeline is at the seabed and the lifting device for deployment of the second pipeline end has to carry the full load of the pipeline. This load can in total be up to 650 metric tons. The structure must in this case be dimensioned to carry the total load of the pipeline in addition to the outboard connecting part, when the second end pipeline and the outboard connecting part is lowered to the seabed.
[0014] In the reverse action, when retrieving the pipeline from the seabed, the lifting device for retrieval of the pipeline end that is lifted first from the seabed towards the sea level, must carry the full load of the pipeline, while the lifting device that is lifting the pipeline that is retrieved last from the seabed will only carry a part of the weight of the pipeline.
[0015] Publication NO 331032 describes a tool for lowering and retrieval of a second pipeline end that is provided with a second or outboard connecting part designed for mating with and connection to a first or inboard connecting part on the seabed. The tool comprises a lifting frame, a guiding part that is an extension of the lifting frame. A lifting yoke is connected to the lifting frame through lifting arms. The tool is arranged so that can be brought to the surface for reuse as a whole.
[0016] In this publication, it is necessary that the inboard connecting part is lowered and installed at the seabed before the second end is lowered.
[0017] The guiding part of the tool is guided by a control structure on the inboard connecting part so that the outboard connecting part is landed on the seabed in a position near the inboard connecting part. In this construction, it is necessary to lower and arrange the inboard connecting part at the seabed before lowering the outboard connecting part.
[0018] In the invention according to the application, it is not necessary to have the inboard connecting part at the seabed before lowering the pipeline. On the other hand, it is therefore necessary to have a lifting tool that is not dependent on the inboard connecting part when lowering the pipeline end, and which has a high load capacity.
OBJECTS OF THE INVENTION
[0019] The objective of the present invention is to provide a lifting device for lowering from a surface, alternatively later retrieval to a surface, which lifting device is beneficial over the previous technology with respect to the following issues:
[0020] The lifting device has the advantage that it has a high load capacity and can carry the full load of the pipeline or flex line.
[0021] The lifting device can be installed before the inboard connecting part is arranged on the seabed.
[0022] The lifting device is less complicated in use than previously known lifting devices for this purpose.
[0023] The lifting device allows the flexible pipeline to swivel (rotate freely in respect to the lifting device) during landing. This is essential when installing torsion stiff large flexible pipelines.
[0024] The lifting device is time efficient and therefore cost effective because it is only the yoke that is retrieved from the seabed when the pipeline is lowered to the seabed. Or, in the opposite case: lowered to the seabed when the pipeline is retrieved from the seabed. The rest of the lifting device is remaining in the seabed together with the pipeline and the outboard connecting part.
[0025] The lifting device allows for a safe (low risk of damage) and secure way of releasing and re-docking of the yoke with minimum of help from the ROV
[0026] The lifting device has several main components but is in one embodiment of the invention designed so that each main component is in the form of a replaceable module.
[0027] The lifting device is primary used to deploy a second end of a flexible pipeline, but can also be used to deploy a first end of the flexible pipeline with some modifications made on to the lifting device. The problems to be addressed can be somewhat different when the first end is to be laid from a surface vessel and down to the seabed compared with deployment of the second end as described above. When the first end is lowered down to the seabed there lifting device only need to carry a portion of the weight of the pipeline since the remaining part of the pipeline is arranged at the surface vessel. The pipeline is therefore lowered from two connection points on the surface vessel.
[0028] When the second end of the pipeline is lowered down to the seabed, the lifting device has to carry the full weight of the pipeline, because the remaining portion of the pipeline is arranged at the seabed and the lifting device is the only connection with the surface vessel.
[0029] All through the specification including the claims, the words “lifting device”, “yoke”, “hang off clamp” “inboard connecting part”, “second connecting part”, “lifting arms”, “arm locks”, “lock pins”, “guide post”, “guide funnel”, “landing structure”, “pipeline”, “inboard hub”, “outboard hub”, are to be interpreted in the broadest sense of the respective terms and include all similar items in the field known by other terms, as may be clear to persons skilled in the art.
[0030] Restriction/limitation, if any, referred to in the specification, is solely by way of example and for understanding the present invention.
SUMMARY OF THE INVENTION
[0031] The invention relates to a lifting device for lowering a pipeline end from a water surface to a seabed, alternatively later retrieval of the same from the seabed to the water surface, said pipeline end being provided with an outboard connecting part designed for mating and connection with an inboard connecting part on the seabed. The invention is distinctive in that the lifting device comprises a hang off clamp adapted for connection with the outboard connecting part,
[0032] at least one lifting arm pivotably connected to the hang off clamp at a respective first end of said at least one lifting arm and;
[0033] a yoke, said yoke being adapted to be releasable connected to the at least one lifting arm at a respective second end of said lifting arm, said at least one lifting arm having a locking arrangement adapted for securing the at least one lifting arm to the hang off clamp in a non-rotational resting position.
[0034] The invention provides a lifting device where the yoke could be retrieved from the seabed or lowered towards the seabed. The yoke could easily be disconnected from the lifting arms and be reused, while the remaining part are attached to the outboard connecting part. There is also no need for the inboard connecting part to be arranged at the seabed before the lifting device is lowering the outboard connection part to the seabed.
[0035] In a preferred embodiment of the lifting device according to invention the lifting device comprises two lifting arms arranged one on each side of the hang off clamp. This provides a uniform lifting of the outboard connecting part and the pipeline.
[0036] In yet another preferred embodiment of the lifting device according to the invention the hang off clamp comprises a bottom frame and brackets, said hang off clamp being adapted for receiving the outboard connecting part.
[0037] In another preferred embodiment of the invention the at least one arm lock is engaging a column in the hang off clamp to secure the lifting arm in the non-rotational position between a vertical connection position where the lifting arms are attached to the yoke and a resting position where the lifting arms are disconnected from the yoke and are adapted to rest on an inboard connecting part 10 connected to the outboard connecting part. This provides easy disconnection of the yoke from the lifting arms and bottom frame.
[0038] In another embodiment of the lifting device according to the invention the yoke has at least one locking mechanism for locking the yoke to the at least one lifting arm.
[0039] In yet another embodiment of the lifting device according to the invention the yoke has at least one guiding funnel arranged beneath the at least one locking mechanism. The at least one funnel provides easy connection between the yoke and the at least one lifting frame.
[0040] In another embodiment of the lifting device according to the invention the yoke have two guiding funnel and two locking mechanism, arranged in pair. This provides a more stable or even lifting of the arrangement.
[0041] In another embodiment of the lifting device according to the invention, the arm locks and locking mechanism are actuated by an ROV.
[0042] In yet another lifting device according to the invention, the lifting arms are adapted to rest on the inboard connecting part in a resting position.
[0043] In yet another embodiment of the lifting device according to the invention the at least one locking mechanism comprises;
[0044] a bore adapted to receive a free end of the lifting arms;
[0045] a locking pin arranged perpendicular to the bore, said locking pin is adapted to engage with an eye arranged on the lifting arm;
[0046] said locking mechanism being is adapted to lock the yoke and the hang off clamp together when lowering or retrieving the outboard connecting part.
[0047] In yet another embodiment of the lifting device according to the invention the lifting arms are connected to the brackets through trunnions.
[0048] The lifting arms are adapted to rotate in relation to the bottom frame between a substantially vertical position towards a position where the arms are resting on the inboard connecting part.
[0049] The invention also relates to a method for lowering a pipeline end from a water surface by using of a lifting device for receiving an outboard connection part designed for mating and connecting with an inboard connecting part arranged on the seabed, said lifting device comprising a hang off clamp with at least one lifting arm rotatably connected to the hang off clamp and a yoke releasably connected to the at least one lifting arm, said method comprising the following steps:
connecting the yoke to the lifting arm, lowering the lifting device with outboard connecting part and pipeline end towards the seabed, swiveling the lifting arm to a position suitable for non-rotational connection with the hang off clamp, connecting the lifting arm to the hang off clamp, releasing the yoke from the at least one lifting arm, retrieval of the yoke to the water surface.
[0056] The method for lowering a pipeline end from a water surface further rela, wherein after the inboard connecting part and the outboard connecting part are connected, the non-rotational connection between the at least one lifting arm and the hang off clamp is released, said at least one lifting arm is further lowered down to a resting position on the inboard connection part.
[0057] The invention also relates to a method for retrieval of a pipeline end from a seabed by use of a lifting device for receiving an outboard connection part designed for mating and connecting with an inboard connecting part arranged on the seabed, said lifting device comprising a hang off clamp with at least one lifting arm rotatably connected to the hang off clamp, and a yoke releasably connected to the at least one lifting arm, said method comprising the following steps:
swiveling of the at least one lifting arm to a position suitable for non-rotational connection with the hang off clamp, lowering the yoke towards the at least one lifting arm, connecting the yoke to the lifting arm, releasing the non-rotational connection between the at least one lifting arm and the hang off clamp, retrieval of the lifting device with the outboard connecting part and the pipeline end to the water surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] Having described the main features of the invention above, a more detailed and non-limiting description of an exemplary embodiment will be given in the following with reference to the drawings.
[0063] FIG. 1 shows in perspective view an elevated view of the outboard connecting part of a connector device together with a lifting device according to the invention, viewed from the side.
[0064] FIG. 2 shows in a perspective view the lifting device according to the invention attached to the outboard connecting part, viewed from the side.
[0065] FIG. 3 shows a cross section of the lifting device and the outboard connecting device according to the invention along a line A-A shown in FIG. 2 .
[0066] FIG. 4-10 shows the sequences of lowering the lifting device with outboard connecting part and the pipeline end towards the landing structure to be connected to the inboard connecting part. The figures also show the disconnection of the yoke from the hang off clamp.
DETAILED DESCRIPTION OF THE INVENTION
[0067] With reference to the FIGS. 1-3 , an embodiment of a lifting device 100 according to the invention will now be described. FIG. 1 shows an outboard connecting part 20 for connecting a pipeline to, for instance, another pipeline at the seabed. The connection could also be between a pipeline that is lowered to the seabed and a subsea arrangements (not shown) arranged on the seabed.
[0068] The FIGS. 1-3 shows the outboard connecting part 20 as it appears without being connected to a flexible pipeline end (not shown).
[0069] The outboard connecting part 20 is to be guided towards an inboard connecting part 10 and a landing structure 30 to be able to make the connection between the inboard and outboard connecting parts 10 and 20 . The outboard connecting part 20 ′ and the landing structure 30 are shown in FIG. 5-10 .
[0070] It is also possible to lower the pipeline end with the outboard connecting part 20 on the landing structure 30 before the inboard connection part 10 are deployed on the seabed.
[0071] The lifting device 100 is suitable for different designs of the outboard connecting part 10 , an example of an outboard connecting part described in Norwegian application NO20150285, filed simultaneously by the same applicant and inventor. The title of this application is “Double guide funnel flexible connection system.” This outboard connection device is advantageous when lowering a pipeline end on the landing structure without immediately connecting the pipeline end to the inboard connecting part.
[0072] In the FIGS. 1-4 , only the outboard connecting part 20 is shown. The outboard connecting part 20 is adapted to be connected to a hang off clamp 11 .
[0073] The hang off clamp 11 comprises a bottom frame 12 . The outboard connecting part 20 is adapted to rest inside the bottom frame 12 of the hang off clamp 11 . The hang off clamp 11 is dimensioned so that the outboard connecting part 20 could be connected to the hang off clamp 11 . The outboard connecting part 20 could also be released from the hang off clamp 11 . Brackets 13 a, 13 b are arranged at both sides of the bottom frame 12 . The brackets 13 a, 13 b having each a protrusion 14 arranged at the inside of the brackets 13 a, 13 b so that the protrusions are 14 facing each other.
[0074] The protrusions 14 on the hang off clamp 11 are adapted to engage with corresponding holes 15 arranged at each sides of the outboard connecting part 20 and provides a connection between the outboard connecting part 20 and the hang off clamp 11 .
[0075] The hang off clamp 11 further comprising two lifting arms 3 a, 3 b attached to the outside of the brackets 13 a, 13 b. A first end 3 a ′ 3 b ′ of the lifting arms 3 a, 3 b are connected to the respective outside of the brackets 13 a, 13 b through trunnions 4 a, 4 b. The lifting arms 3 a, 3 b are adapted to rotate around the trunnions 4 a, 4 b.
[0076] The lifting arms have each an opposite free second end 3 a ″, 3 b ″ of the lifting arms 3 a, 3 b. There are arranged an eye 5 a, 5 b on each of the lifting arms 3 a, 3 b at or near the free end 3 ″, 3 b ″ of the lifting arms 3 a, 3 b. Between the first end 3 a ′ 3 b ′ and the second end 3 a ″, 3 b ″of the lifting arms 3 a, 3 b there are arranged arm locks 6 a, 6 b. The arm locks 6 a, 6 b are arranged in a position on the lifting arms 3 a, 3 b so that it corresponds with a column 16 a, 16 b in each of the brackets 13 a , 13 b when the lifting arms 3 a, 3 b are lowered towards the brackets 13 a, 13 b The position of the arm locks 6 a, 6 b at the lifting arms 3 a, 3 b could have any positions suitable within the objective of the invention to make the connection between the lifting arms 3 a, 3 b and the brackets 13 a, 13 b so that the lifting arms are prevented from further rotation.
[0077] The arm locks 6 a, 6 b have each an L-shaped part 17 a, 17 b that could be rotated outwardly and engage with the column 16 a, 16 b of the bracket 13 a, 13 b.
[0078] In the center of the hang off clamp 11 , there is an opening 18 , which has a diameter greater than the pipeline so that the pipeline is allowed to be connected to the outboard connecting part 20 through the opening 18 .
[0079] The FIG. 1-3 also illustrates a yoke 2 , which is releasable connected to the hang off clamp 11 through the lifting arms 3 a, 3 b. In the FIGS. 1-3 , the yoke 2 is shown in a released position from the hang off clamp 11 .
[0080] In FIG. 4 , the yoke is connected to the hang off clamp in 11 in a connected position. The yoke 2 can be disconnected from the lifting arms 3 a, 3 b and be brought up to the surface for reuse, while the hang off clamp 11 is remained at the seabed together with the outboard connecting part 20 .
[0081] The yoke 2 has locking mechanisms 7 a, 7 b arranged at each side of the yoke 2 . The locking mechanism 7 a, 7 b are similar on both sides of the yoke 2 and are shown in detail in FIG. 3 . The locking mechanism 7 a, 7 b comprises a yoke, funnel 8 a, 8 b arranged beneath a vertically aligned bore 9 a, 9 b which is adapted to receive the second end 3 a ″, 3 b ″ of each of the lifting arms 3 a, 3 b. A locking pin 50 a, 50 b is arranged perpendicular to the bore 9 a, 9 b and is slidable in relation to the bore 9 a, 9 b. The locking pin 50 a, 50 b is adapted to be pulled out of the bore 9 a, 9 b in an unlocked position.
[0082] Each of the lifting arms 3 a, 3 b is adapted to be arranged within the bore 9 a, 9 b of the locking mechanism 7 a, 7 b and the eye 5 a, 5 b is then corresponding with the position of the locking pin 50 a, 50 b. The locking pin 50 a, 50 b could then be pushed through the eye 5 a, 5 b to hold the lifting arm 3 a, 3 b in a secured position within the locking mechanism 7 a, 7 b, this is referred to as locked position between the yoke 2 and hang off clamp 11 . The yoke funnels 8 a, 8 b are positioned beneath the bores 9 a, 9 b in order to guide the lifting arms 3 a, 3 b so that they engage more easily with the bores 9 a, 9 b.
[0083] The outboard connecting part 20 comprises an outboard reaction plate 26 (shown in FIG. 2 ) with a circular opening in the middle of the plate. An outboard hub 25 (shown in FIG. 3 ) fits in the opening of the reaction plate 26 . The outboard hub 25 is adapted to be connected to a pipeline end (not shown) that shall be lowered to the seabed. In the opposite end of the outboard hub 25 , there is arranged a clamp connector 22 for connecting the outboard hub 25 to an inboard hub 42 arranged on the inboard connecting part 10 .
[0084] There is also arranged at least one guide funnel 21 on the outboard connecting part 20 . In FIGS. 1-3 there are shown an embodiment with two guide funnels 21 arranged on the outboard connecting part 20 .
[0085] It is to be noted that the outboard connecting part 20 ′ has different orientations in the Figures. In FIG. 1-4 , the funnels 21 are arranged at one of the sides of the outboard connecting part 20 .
[0086] When the outboard connecting part 20 is lowered down to the seabed the funnels 21 will mate with at least one guidepost 40 arranged on a landing structure 3 arranged on the seabed, the outboard connecting part 20 ′ together with the bottom frame 12 and the brackets 13 a, 13 b are rotated 90° so that the guide funnels 21 are oriented downwards. The at least one guide funnel 21 is then adapted to mate with the at least one guideposts 40 . This is shown in FIG. 5 .
[0087] FIGS. 4 to 10 shows sequences of the lowering of the pipeline end to the seabed with the lifting device 100 according to the invention.
[0088] In the figures, the inboard connecting part is already installed at the seabed before lowering the outboard connecting part 20 . This is not a requirement. The inboard connecting part 10 could be installed after the lowering of the outboard connecting part 20 . The mating operation takes place between the outboard connecting part 20 and the landing structure 30 with the at least one guidepost 40 as assisting means. The at least one guidepost 40 is arranged perpendicular to the landing structure 30
[0089] FIG. 4 shows that position where the outboard connecting part 20 is lowered from the sea surface, for example from a surface vessel (not shown). The outboard connecting part 20 is oriented with the guide funnels 21 arranged at one of the sides of the outboard connecting part 20 , as described above. The yoke 2 is connected via the lifting arms 3 a, 3 b by the lock pins 7 a, 7 b to the hang off clamp 11 . The outboard connecting arrangement 20 and the hang off clamp 11 are hanging from the lifting arms 3 a, 3 b beneath the yoke 2 . The lifting arms 3 a, 3 b are arranged in a vertical line at each side of the outboard connecting part 20 . This position is referred to as a connecting position of the lifting arms 3 a, 3 b.
[0090] In FIG. 5 the at least one funnel 21 of the outboard connecting part 20 is downwardly aligned with the at least one guidepost 40 . The Figure shows the position when the at least one funnel 21 initially mate with the at least one guidepost 40 arranged on the landing structure 30 . The yoke 2 is in this position still connected to the lifting arms 3 a, 3 b.
[0091] In FIG. 6 the at least one funnel 21 is engaging with the at least one guidepost 40 (shown in FIG. 5 ) and the outboard connecting part 20 is resting on the landing structure 30 .
[0092] The yoke 2 is further lowered down towards the seabed so that the lifting arms 3 a, 3 b are rotated around the trunnions 4 a, 4 b, from a substantially vertical position to an non-rotational position, where the free end of the lifting arms 3 a ″, 3 b ″ are brought to a position closer to the landing structure 30 . The position of the lifting arms are approximately within a range of 0-45° from a vertical line through the trunnions 4 a, 4 b. This non-rotational position is shown in FIG. 7 .
[0093] The arm locks 6 a, 6 b are in this position adapted to be connected to the brackets 13 a, 13 b. The L-shaped part 17 a, 17 b is rotated approximately 90° towards the respective brackets 13 a, 13 b. The L-shaped part 17 a, 17 b is then entering the column 16 a, 16 b and the arms 3 a, 3 b are locked to the hang off clamp 11 . The connection is preferably performed by an ROV.
[0094] When the lifting arms 6 a, 6 b are connected to the brackets 13 a, 13 b through the arm locks 6 a, 6 b, the lifting arms 3 a, 3 b are fixed in this position until the arm locks 6 a, 6 b are released from the brackets 13 a, 13 b. The release of the lifting arms 3 a, 3 b is preferably performed by an ROV (not shown). The locking mechanism 6 a, 6 b described, is an embodiment of the locking mechanism to lock the lifting arms in a position. Other arrangements of the locking mechanism 6 a , 6 b is possible and are embodiments of the invention.
[0095] FIG. 8 shows a position when the yoke 2 is released from the lifting arms 3 a , 3 b. The lock pins 7 a, 7 b are released from the eye 5 a, 5 b of the lifting arms 3 a , 3 b as described earlier. This is preferably performed by an ROV but other releasing arrangement of the lock pins 7 a, 7 b are also embodiments of the invention.
[0096] FIG. 9 shows the mating of the outboard connecting part 20 and inboard connecting part 10 in a conventional manner with a stroke tool 44 installed between the first connecting part 10 and the outboard connecting part 20 . One end of the tool 44 is arranged in a slot 23 in the reaction plate 26 of the outboard connecting part 20 as shown in FIG. 3 . The other end is arranged in a similar slot (not shown) on an inboard reaction plate 19 of the inboard connecting part 10 . The stroke tool 44 is adapted to move the outboard connecting part 20 towards the inboard connecting part 10 , into a position where an inboard hub 42 arranged on the inboard connecting part 10 is abutting the outboard hub 25 on the outboard connecting part 20 .
[0097] FIG. 10 shows the situation when the inboard hub 42 and the outboard hub 25 are connected to each other through a clamp connector 22 . The clamp connector 22 is normally attached to the outboard hub 25 on the outboard connecting part 20 before it is connecting the two parts together. After the connection of the inboard connecting part 10 and the outboard connecting part 20 , the arm locks 6 a, 6 b are released from the brackets 13 a, 13 b. The L-shaped part of the arm locks 17 a, 17 b is released from the column 16 a, 16 b. The lifting arms 3 a, 3 b are rotated further down towards the inboard connecting part 10 until the lifting arms 3 a, 3 b rests on the inboard connecting part 20 . In this position, the lifting arms ( 3 a, 3 b ) are in a resting position. The lifting arms ( 3 a, 3 b ) shown in the figure are not attached to the inboard connecting part 10 , but it is an embodiment of the invention to attach the lifting arms to the inboard connecting part in a releasable connection.
[0098] The FIGS. 4 to 10 shows sequences of the lowering and mating of the inboard 10 and outboard 20 connecting parts using the lifting device. It is to be understood that the reverse action of the lifting device 100 is also possible.
[0099] The lifting arm is moved from the resting position to the non rotational position and locked to the brackets 13 a, 13 b as described earlier.
[0100] The yoke 2 is lowered to a position where it engages with the eyes 5 a, 5 b of the lifting arms 3 a, 3 b. The yoke 2 could then be connected to the lifting arms 3 a, 3 b through the lock pins 7 a, 7 b, and the outboard connecting part 20 with the attached pipeline could then be lifted to the sea level by the lifting device 100 .
[0101] The present invention has been described with reference to a preferred embodiment and some drawings for the sake of understanding only, and it should be clear to persons skilled in the art that the present invention includes all legitimate modifications within the ambit of what has been described hereinbefore and claimed in the appended claims.
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A lifting device for lowering a pipeline end from a water surface to a seabed, alternatively later retrieval of the same from the seabed to the water surface, said pipeline end being provided with an outboard connecting part designed for mating and connection with an inboard connecting part on the seabed. The lifting device includes a hang off clamp adapted for connection with the outboard connecting part, at least one lifting arm pivotably connected to the hang off clamp at a respective first end of said at least one lifting arm and a yoke, said yoke being adapted to be releasable connected to the at least one lifting arm at a respective second end of said lifting arm, said at least one lifting arm having a locking arrangement for securing the at least one lifting arm to the hang off clamp in a non-rotational resting position. A method for lowering of a pipeline end from a water surface and retrieving a pipeline end from a seabed by use of the lifting device is also disclosed.
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FIELD OF THE INVENTION
[0001] The present invention belongs to the field of footwear engineering, and describes a self-scalable casual footwear that allows involve two subsequent footwear sizes, both on foot length and several widths/perimeters and heights that the same foot length can hold without the need for additional components for adjustment, such as laces, rubber bands, straps, velcro, zippers, hooks, eyelets or any other that is treated as a resource for the purpose of this invention.
BACKGROUND OF THE INVENTION
[0002] The availability of footwear in the market is through not self-scalable fixed numbering, requiring the user understands the dimensions of their feet in order to buy a footwear such as length and width measures. Therefore, in a global scale, some markets have besides length the choice of the width that can vary between three or more measurements, thus generating an increase in both volume and in logistics and storage of these products in stores, consequently requiring larger storage area. In other markets there is available only the choice of the size (length of the footwear) with a standard width determined by each manufacturer, so limiting the consumer choice. This way, the proposed footwear aims at overcoming this limitation by providing its users with increased comfort due to its flexibility.
STATE OF THE ART
[0003] There have been presented several solutions/adaptations of footwear in order to allow the use of two subsequent footwear sizes, but none that met so broadly such needs as in the present invention. For example:
[0004] The document CN20237514U differs from the present invention because only the requisite of width of the footwear is met, the outsole being static in relation to the length. The present invention meets both the width and length needs in all of its component parts and is intended for adult female public.
[0005] The document ES1061431 is not in conflict with the present invention, because it is a product for the children's segment, as the outsole allows only adjustment in length, the width getting adjustable by a velcro system. Differently, the present invention meets both the width and length needs in all its component parts.
[0006] The document FR1562221A is not in conflict with the present invention, because the adjustment takes place only in the length of the foot and in the heel region.
[0007] The document GB913182A is different from the present invention, since it refers only to elasticity on the footwear length.
[0008] The document U.S. Pat. No. 8,935,861B2 is not in conflict with the present invention, as the outsole does not include lengthening the width of the foot.
[0009] The document U.S. Pat. No. 8,938,890B2 differs from the present invention, since the described outsole has a manual adjustment in the length of the footwear and does not include a width sizing. The upper restricts the lengthening on the instep (midfoot), limiting the area, offering lengthening only in the hindfoot and forefoot region.
BRIEF DESCRIPTION OF THE INVENTION
[0010] The present invention has the objective of providing the use of a footwear which allows to involve two subsequent footwear sizes, since, at the same time as different people with the same length of feet may have different widths/perimeters, either in the regions of the hindfoot, midfoot and forefoot, the individual himself/herself does not have symmetry of the members in question.
[0011] By associating elastic materials with techniques in the production process and based on numbering anthropometric scale of French point used in Brazil, that determines the difference in size of each spacing each 6.66 millimeters for female footwear, it is assigned the size of a footwear multiplied by 6.66 millimeters, and, for example, size 35 corresponds to the length of 233.1 millimeters, considering this the actual measurement of the foot length.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 shows a perspective view of the footwear described in the present invention;
[0013] FIG. 2 shows the mounting insole, showing the narrower areas ( 5 ) as described in the present invention;
[0014] FIG. 3 shows the outsole as described in the present invention;
[0015] FIG. 4 shows the bi-elastic material of upper, highlighting the three layers that comprise it: the first and third layer ( 8 ) of synthetic knitted fabric and the second layer ( 9 ) of latex foam material with SBR; and
[0016] FIG. 5 shows a side sectional view of the outsole highlighting the two layers ( 6 and 7 ) that compose it.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention relates to a casual footwear that allows involve two subsequent footwear sizes, comprising an upper of bi-elastic material ( 1 ) and a mono-elastic ( 2 ), an outsole of bi-material ( 3 ) and a mounting insole ( 4 ).
[0018] The upper, the top part of the footwear, is manufactured with a hi-elastic material ( 1 ) and a mono-elastic material ( 2 ). The first ensures a lengthening in the vertical and horizontal direction (length and width of feet), and is composed of materials having an elastic property and divided into three layers: the first and third ( 8 ) layers of synthetic knitted fabric with a yarn composition in the range of 83% to 97% of PES (polyester), and is more suitable the composition of 90% PBS and 10% of PUR. The composition of the fabric yarns may be of synthetic or natural origin associated with a PUR yarn in the process of manufacturing the knitting for interlacing the yarns, thereby securing its elasticity. There also can be used synthetic laminates with a bi-elastic property to replace the knitted fabric. The second layer ( 9 ) is composed of latex foam material with SBR (styrene butadiene rubber) with 1.3 to 5 mm of thickness and specific gravity of 140 kg/m 3 and 350 kg/m 3 , the most suitable thickness and specific gravity being 2 mm and 270 kg/m 3 .
[0019] The union between the layers is accomplished with an adhesive film of thermo-sticky PU, but other adhesives alternatives may also be applied in the liquid state (when the adhesive is applied at ambient temperature without the need for heat usage to reactivate its properties) or in the semi-solid/paste state (hot melting, when it is necessary to liquefy it with a high temperature to activate its stickiness properties).
[0020] The mono-elastic material ( 2 ) has only lengthening in its width, and is composed of a base of PES (polyester) fabric and a PU (polyurethane) coating, and is considered a “laminate fabric” or “synthetic laminate”. It is set in the bi-elastic material ( 1 ) by an adhesive film with thermo-sticky PU resin and seams around the edges, it is arranged in three parts (pieces) that limit the excessive lengthening of the footwear in the heel area, toecap (front of the footwear) and parts of the sides. In areas where it is not fixed, it allows the bi-elastic material ( 1 ) to hold the property of the lengthening, allowing the footwear to fit the size and width of the foot without causing an excessive pressure (tighten the foot) or a play (the footwear drops out of the foot), allowing for a safe walking.
[0021] The mounting insole ( 4 ) is developed with a web of 100% of PES, a resin non-woven fabric with a grammage of between 140 and 500 g/m 2 and with specific design, so that, during the manufacturing process of positioning the upper in the mold, allows the length accuracy and not leaving the footwear loose or warped, and when gluing/setting the outsole, the narrower areas ( 5 ) are cut and removed to allow the lengthening of the footwear not to be compromised.
[0022] The bi-material outsole ( 3 ) of TR (thermoplastic) forms two layers, the first ( 7 ) being soft and elastic with a hardness between 20 and 25 Shore A, preferably of 22 Shore A and a thickness between 0.9 and 2.0 mm, preferably of 1.5 mm, in the sole of the foot region (forefoot and midfoot) enabling the lengthening safely, since when reducing the thickness, a low resistance to lengthening occurs and otherwise make rigid the material for lengthening, and a thickness between 8 and 11 mm, preferably of 9 mm, in the heel region (hindfoot), guaranteeing the quality to absorb the impact when walking, without deformation or excessive rigidity.
[0023] The second layer ( 6 ), which is in contact with the ground, is soft and resistant to wear (abrasion) with a hardness between 70 and 80 Shore A, preferably of 80 Shore A. The wavy design on its surface enables a greater adherence and ensures the safety when walking, and its application is divided distinctly in the three regions of the foot, more statically covering the entire area of the hindfoot, without significant sizing, in the midfoot/forefoot divided into fifteen insulated parts and with distinct shapes enabling the outsole lengthening in the width and length of the foot and in the forefoot statically occupying part of the toecap/tip of the footwear without significant sizing.
[0024] While the invention has been described widely, it is obvious to those skilled in the art that various changes and modifications may be made seeking design improvements without said changes are not covered by the scope of the invention.
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The present invention relates to a self-scalable casual footwear that allows involve two subsequent footwear sizes, comprising an upper of bi-elastic material ( 1 ) and a mono-elastic ( 2 ), a bi-material outsole ( 3 ) and a mounting insole ( 4 ). Such footwear does not require additional components to fit, such as laces, rubber bands, straps, velcro, zippers, hooks, eyelets or any other that is treated as a resource for the purpose of this invention.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from and the benefit of PCT Application No. PCT/EP2007/009041, filed on Oct. 18, 2007; and German Patent No. DE 10 2006 050 474.7, filed on Oct. 20, 2006; and German Patent DE 10 2007 015 600.8, filed on Mar. 29, 2007; all entitled “Door Lining, Especially for a Motor Vehicle, and Production Method”, which are herein incorporated by reference.
BACKGROUND
[0002] The present invention relates to a separating means, which divides the space between the sheet metal of a door and a door lining into an outer wet area and an inner dry area, and consists of a composite of a separating film and an absorbent nonwoven material. The present invention also relates to a method for producing a separating means and to a vehicle door.
[0003] The generic separating means is known, for example, from DE 103 26 154 A1, U.S. Pat. No. 6,197,403 B1, DE 35 10 018 C2 and G 82 25 069. The vehicle door described in the documents is provided with a door lining on the interior side, the space that is enclosed by the outer sheet metal of the door and the door lining being divided by means of a separating means into an outer wet area and an inner dry area.
[0004] The object of the present invention was to improve the acoustic properties of the separating film.
[0005] The object is achieved by a separating means which divides the space between the sheet metal of the door and the door lining into an outer wet area and an inner dry area, said means consisting of a composite of a separating film and an absorbent nonwoven material and the absorbent nonwoven material consisting of a base web of plastic fibers.
SUMMARY
[0006] It was entirely surprising and unexpected for a person skilled in the art that improved acoustic absorption properties can be achieved with the separating means according to the invention. As a result, the noise in the interior of the vehicle is significantly reduced, which enhances the traveling comfort of the vehicle occupants.
[0007] According to the invention, the separating means comprises an absorbent nonwoven material with a base web of plastic fibers. The plastic fibers are preferably polyester fibers and/or polypropylene fibers. With particular preference, the weight ratio between polyester fibers and polypropylene fibers is from 25:75 to 35:55, with particular preference however 30:70.
[0008] The base web preferably has a weight per unit area of from 150 to 500 grams/m 2 , with most particular preference 170 to 220 grams/m 2 .
[0009] The base web preferably has a thickness of from 5 to 30 mm, preferably 7 to 20 mm.
[0010] The separating film that is likewise present according to the invention is preferably produced from polyolefin, with particular preference from polypropylene. The film preferably has a thickness of between 0.1 and 4 mm, preferably 1 to 2 mm.
[0011] The separating means according to the invention preferably additionally comprises a top web. The top web preferably consists substantially, with most particularly preference consists completely, of polypropylene (PP), in order to improve the adhesion to the PP backing. One function of the top web may be to provide protection for the comparatively fibrous base web.
[0012] The absorbent nonwoven material is preferably arranged between the top web and the separating film.
[0013] However, it is also conceivable to produce the base web from some other plastics material, for example polyether sulfone (PES), and then provide it with an adhesion promoter, for example polyethylene powder, in order to make possible or improve the bond between the PP backing and the base web.
[0014] The present invention also relates to a method for producing a separating means which comprises a separating film and an absorbent nonwoven material, in which method the separating film and the absorbent nonwoven material are jointly deformed, preferably thermoformed.
[0015] The separating means is preferably the separating means according to the invention described above.
[0016] During the thermoforming, the absorbent nonwoven material and the separating film are preferably not only deformed but also integrally bonded to each other. This integral bonding takes place in particular by the absorbent nonwoven material and/or the separating film being heated to such a degree that, after or when they are placed one on top of the other, possibly with the application of pressure, they integrally bond to each other when they subsequently cool down. This preferred embodiment of the method according to the invention has the advantage that no adhesive has to be used between the separating film and the absorbent nonwoven material.
[0017] The separating film is preferably heated before the deforming. The separating film is in this case preferably heated at least up to its plastication temperature.
[0018] The present invention also relates to a vehicle door comprising the separating means according to the invention or a separating means produced by the method according to the invention.
[0019] The vehicle is preferably a motor vehicle, in particular a passenger car or a truck.
DRAWINGS
[0020] The invention is explained below with reference to FIGS. 1 to 5 . These explanations are given merely by way of example and do not restrict the general concept of the invention. The explanations apply equally to all aspects of the subject matter of the present invention.
[0021] FIG. 1 shows the heating of the separating film.
[0022] FIG. 2 shows the arranging of the absorbent nonwoven material above the separating film.
[0023] FIG. 3 shows the joint thermoforming of the separating film and the absorbent nonwoven material.
[0024] FIG. 4 shows the punching of the composite of separating film and absorbent nonwoven material.
[0025] FIG. 5 schematically shows the separating means according to the invention.
DETAILED DESCRIPTION
[0026] Firstly, as shown in FIG. 1 , the still planar separating film 1 is clamped into a first frame 2 , positioned above a thermoforming mold 3 and heated from above by means of a heater 4 , until it has reached at least its plastification temperature. The heating 4 of the separating film 1 may take place by introducing energy in any way familiar to a person skilled in the art, for example by means of radiation, contact heating, convection, ultrasound or a combination of these. After the method step of heating 4 , an absorbent nonwoven material 5 , which is specified in more detail below and is held by a further frame 6 , is arranged above the separating film ( FIG. 2 ). By means of a punch 7 , which can be moved in the direction of the thermoforming mold 3 and may, for example, consist of a foam 10 cm thick, the absorbent nonwoven material 5 and the separating film 1 are jointly pressed into the thermoforming mold 3 and simultaneously drawn onto the three-dimensionally formed mold surface thereof by a vacuum V ( FIG. 3 ). The still present residual heat of the separating film 1 has the effect that the separating film 1 and the absorbent nonwoven material 5 thereby enter into an intimate bond, in particular an integral bond, which can subsequently be brought into the desired form and provided with the necessary recesses by punching (die W in FIG. 4 ). After that, the punch 7 and the thermoforming mold 3 are moved away from each other again and the separating means produced can be removed. Alternatively, the separating film 1 is heated up and then pre-blown. In a next step, a thermoforming punch moves into the pre-blown separating film 1 and a vacuum is applied, so that the separating film comes to lie against the thermoforming punch. Subsequently, the absorbent nonwoven material 5 is pressed with a foam punch onto the thermoformed separating film. The method according to the invention can be carried out very easily and at low cost. The deforming of the separating film and of the absorbent nonwoven material and the integral bonding thereof take place in one method step, so that the method according to the invention can be carried out much more easily than the methods according to the prior art.
[0027] Preferably used as the absorbent nonwoven material 5 is a composite with a base web 8 , which consists of polyester fibers and polypropylene fibers, preferably in a weight ratio of from 25:75 to 35:55, in particular approximately 30:70. A top web 9 , which contains exclusively polypropylene fibers and lends the composite a certain strength, or protects the very fibrous absorbent nonwoven material, is placed onto this sheetlike formation, preferably at least on one side. In the case of an only two-layer absorbent nonwoven material 5 , after pressing onto the separating film 1 , this top web 9 is preferably arranged on the side of the sheet facing away from said film, as represented in FIG. 5 . The layers 8 , 9 are preferably integrally bonded to each other, by sealing or adhesion. The production of the absorbent nonwoven material takes place at a time preferably before the method according to the invention is carried out.
[0028] Preferably, a single-layer absorbent nonwoven material, the at least one surface, preferably both surfaces, of which calendered, i.e. heat-treated for example, in order to strengthen them.
[0029] For better adhesion, PP and/or PE fibers may be admixed to a nonwoven material of PES fibers.
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A separator is provided, such as for dividing an outer wet area from an inner dry area between sheet metal of a vehicle door and the door lining. The separator includes a composite of a separating film and an absorbent nonwoven material. The latter material comprises a base web of plastic fibers.
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BACKGROUND OF THE INVENTION
This invention relates to sealed cable control systems.
DESCRIPTION OF THE PRIOR ART
Cable control systems are commonly used to control or operate a mechanism. A cable control system may include end members which reciprocate, and a third member connected therebetween. The third member or cable transmits the forces exerted by one reciprocating member to the other. Protective boots may be used to isolate members of a cable control system from the environment. In some configurations more than one protective boot may be required. For example, it may be necessary to have one boot at a first end to encompass one of a pair of reciprocating members and a second boot at a distant end to encompass the other reciprocating member. A third boot or conduit may encompass the cable. As the end members or shafts reciprocate within the respective distant boots, the volumes of the boots change. For example, as a shaft is moved in one direction one boot, which encompasses a shaft, collapses and pressure increase occurs within the boot as the boot collapses. As a result of the pressure increase there is a resistance to the movement of the shaft which inhibits the free movement of the control system. Therefore, it is desirable to maintain a relatively constant pressure within two separated boots and the conduit as the reciprocating members extend from a neutral position and then contract from a neutral position.
In a typical system, each of the rigid shafts is protected within a boot and the flexible shaft or cable is protected within a conduit which is adapted to be sealed to each of the two boots. The transfer of air from one boot to the other occurs through the conduit as the shafts reciprocate. This is not a very effective means of transferring air to maintain a relatively constant pressure within the two distant, remote boots. The lack of effective air transfer therefore results in a pressure increase at one point in the system which inhibits the movement of the shafts and cable and therefore renders the control system less effective. There is a corresponding relatively lower pressure at another point in the system which may cause the inspiration of atmospheric contaminants.
In the case of a typical automotive transmission shift cable control the shafts and cable must be totally protected from the environment. As the shaft, encompassed by one boot, retracts the boot collapses and the pressure therein increases, causing a resistance to the movement of the shafts and cable within the boot and conduit. Therefore, it is desirable to have a means to provide a redistribution of air within all points of the sealed cable control system. It is also desirable to have a more effective and efficient means to allow the passage of air from the interior of one boot to the interior of another boot to maintain a relatively constant pressure.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a sealed cable control system which includes reciprocating members, protective boots and an air transfer system to equalize the pressure in the system as the members reciprocate. The air transfer system includes air transfer fittings sealed to a tube therebetween to allow an efficient transfer of air within the system, thereby permitting the maintenance of a closed constant volume, constant pressure environment around reciprocating members including shaft and cable members enclosed herein.
In accordance with the invention, a cable control system comprises a first member and a second member connected by a third member therebetween. The first and second members are each reciprocating members of the control system and desirably are shafts. The first and second members, or shafts, are connected by the third member which is desirably a cable. The first and second members, or shafts, are enclosed in respective sealed protective boots, each of which is sealed to a conduit which encompasses the cable connected between the respective shafts.
Means are also provided for effectively sealing the cable control system from the environment while at the same time efficiently and effectively equalizing the pressure within the sealed system. The invention comprises a sealed cable control system having sealed protective boots or bellows with an integral, internal air transfer system.
An air transfer system comprises a pair of air transfer fittings each of which is sealed at one end to one of two boots. A tube is sealed to the other end of each of the two fittings. The tube is coextensive with the cable between the two boots.
The first air transfer fitting communicates with the interior volume of the first boot, the second air transfer fitting communicates with the second boot, and both fittings communicate with the enclosed volume provided by the tubing which encompasses the conduit or cable.
The air transfer system is constructed to facilitate the passage of air from the interior of one sealed protective boot, through one fitting, then through the tube and to the other fitting and then to the interior of another sealed protective boot, to thereby maintain a relatively constant pressure within the entire cable control system. Preferably, each fitting is adapted to be sealed at one end to the tube and at the other end to a boot which encompasses one of two reciprocating shafts. The tube is sealed to, and joins, the two fittings and is coextensive with the length of the cable or conduit which encompasses the cable. Preferably, the tube is flexible.
The tube joins the two fittings such as to allow effective movement of air within the entire sealed system to equalize the pressure within the entire system. Accordingly, as the shafts and cable move displacing air from one point in the system, it is easily transferred to all other points in the system. For example, air may pass from the interior of one boot through the first fitting, through the tube, through the other fitting and then to the other boot. Thus the air travels from the first boot to the second boot through the tube, as well as through the conduit, without escaping to the atmosphere. Therefore, when a boot collapses a pressure increase is avoided, and as a boot expands, a relatively low pressure is avoided. The inspiration of atmospheric contaminants at a relatively low pressure point in the system is prevented, and a build up of pressure which impedes cable control movement is also avoided as the shafts reciprocate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a part-sectional, fragmentary, front, elevational view of a sealed cable control system which includes shaft and cable members enclosed in a protective boot having an air transfer system.
FIG. 2 is a fragmentary, front, elevational view, partially in of the air transfer system.
FIG. 3 is an enlarged fragmentary, front, elevational view of the air transfer fitting.
FIG. 4 is an enlarged view taken in the encircled portion in FIG. 2.
FIG. 5 is an end view taken along the line 5--5 of FIG. 3.
FIG. 6 is a sectional view generally taken along line 6--6 of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a sealed cable system with an integral air transfer system 10 is shown which embodies the invention. The system 10 has a first end member 12 and a second end member 14 connected to one another by a third member, cable 16 that is fastened to shaft 18 on first end member 14 and shaft 20 on second end member 14. Cable 16 moves axially as shaft 18 on end member 12 and shaft 20 on end member 14 move together. First end 12 basically comprises a molded rod end 22 which is connected to the shaft 18. Shaft 18 is enclosed in a boot 24 which is sealed to shaft 18 by a connector 25. Second end 14 generally comprises a molded rod 26 connected to shaft 20. Shaft 20 is enclosed in a boot 28 which is sealed to shaft 20 by a connector 29. Boot 24 is sealed to an air transfer fitting 30a by a sealed connector 31a. Boot 28 is sealed to an air transfer fitting 30b by a sealed connector 31b.
Referring to FIG. 2, an air transfer fitting 30a is sealed to a tube 32. The fitting 30a is also adapted to be sealed within a conduit 34 which encompasses cable 16. An air transfer fitting 30b is adapted to be sealed to tube 32. The fitting 30b is also adapted to be sealed to conduit 34 which encompasses cable 16.
Air transfer fitting 30a encompasses first end member 12 which comprises shaft 18 and cable 16. Shaft 18 is connected to cable 16 within air transfer fitting 30a. Air transfer fitting 30a is sealed to conduit 34 and conduit 34 is coextensive with cable 16 along its entire length to the second end member 14. Air transfer fitting 30b encompasses shaft 20. Air transfer fitting 30b is sealed to conduit 34 and encompasses cable 16 and shaft 20. Cable 16 is connected to shaft 20 within air transfer fitting 30b.
Referring to FIG. 2, air transfer system subassembly 35 generally comprises the air transfer fittings 30a, 30b and tube 32. Preferably, air transfer system 35 also comprises securing straps 36a, 36b to facilitate sealing of the respective air transfer fittings 30a and 30b to tube 32.
Desirably, air transfer fittings 30a and 30b are essentially similar. Preferably fittings 30a, 30b are identical and will be described by reference to fitting 30a as shown in FIGS. 1-3. Air transfer fitting 30a comprises a cylinder 38 at the other end which is constructed to enclose a shaft 18 (hidden lines in FIG. 3) and which is constructed to be sealed to boot 24 at sealed connector 31a near collar 40 on fitting 30a. Collar 40 is also adapted to be connected to a collar 42 which is secured by ribs 44a, 44b, 44c and 44d to a cylinder 46 which includes grooved section 48 which comprises circumferential grooves 50. Cylinder 46 is connected at collar 52 to cylinder 54 which has a diameter 56 at collar 52 and which tapers to a diameter 58 at its other end and has a conical section 60 adapted to be sealed to conduit 34.
The grooved section 48 has circumferential grooves 50 as shown in FIG. 4. The grooves 50 facilitate the sealing and securing of tube 32 to the air transfer fittings 30a, 30b.
Referring to FIGS. 2 and 3, air transfer system subassembly 35 comprises the air transfer fittings 30a, 30b and tube 32, connected therebetween and sealed to fittings 30a, 30b. Tube 32 is preferably of a flexible material such as rubber, plastic and the like, and has three sections, two end sections 62a, 62b connected to a middle section 63. Each one of the end sections 62a, 62b is respectively sealingly connected to fittings 30a, 30b.
The tightening of strap 36a around tube end 62a causes the interior surface of tube end 62a to flow into grooves 50 of section 48, thereby sealingly fastening tube 32 to fitting 30a. Correspondingly, the tightening of strap 36b causes end 62b to be sealingly fastened to fitting 30b.
Air transfer fitting 30a, as shown in FIGS. 3, 5 and 6, comprises a pair of radial ports 64a, 64b each of which extends from the surface of cylinder 54 through an interior axial channel 66 of fitting 30a, adjacent conduit 34. Ports 64a, 64b are opposed 180° apart on the circumference 55 of cylinder 54, as shown in FIGS. 3, 5 and 6.
Internal channel 66 communicates with ports 64a, 64b and ports 64a, 64b communicate with respective slots 68a, 68b, as shown in FIGS. 3 and 6. Internal channel 66, ports 64a, 64b and slots 68a, 68b thereby form passages 70a, 70b. Slots 68a, 68b are formed by grooves cut into a portion of the exterior of cylinder 54. Preferably, the grooves taper longitudinally as cylinder 54 tapers from diameter 56 to 58.
Air may travel from passages 70a, 70b through the chamber 72 disposed between interior 74 of tube 32 and exterior 75 of conduit 34. Passages 70a, 70b of fitting 30a, chamber 72 and passages 70a, 70b of fitting 30b thereby form continuous passage 76 of the air transfer system 35.
When shafts 18 and 20 move in one direction from a neutral position, air expelled from boot 24 at one end may pass through passages 70a, 70b, formed by interior channel 66, ports 64a, 64b and slots 68a, 68b, of fitting 30a and then through the passages of chamber 72, and then to fitting 30b at the other end and through passages 70a, 70b in the other fitting 30b formed by interior channel 66, ports 64a, 64b and slots 68a, 68b of fitting 30b and into boot 28 at the other end.
When shafts 18 and 20 move in an opposite direction from neutral, air may travel from boot 28 through continuous passage 76 formed by passages 70a, 70b of boot 30b, chamber 72 and passages 70a, 70b of fitting 30a, and into boot 24.
It can thus be seen that there has been provided a sealed cable control system which includes reciprocating members, protective boots and an air transfer system to equalize the pressure in the system as the members reciprocate. The air transfer system includes air transfer fittings sealed to a tube therebetween to allow an efficient transfer of air within the system, thereby permitting the maintenance of a closed constant volume, constant pressure environment around reciprocating members including shaft and cable members enclosed herein.
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A sealed cable control system having an integral, internal air transfer system constructed and arranged to provide a continuous passage comprising a series of integral, internal unrestricted passages within and through the control system to maintain a relatively uniform pressure within the boots and conduit and within the cable control system as the end members of the cable control system reciprocate. An air transfer system which includes air transfer fittings sealed to a tube therebetween to allow an efficient transfer of air within the system, thereby permitting the maintenance of a closed constant volume, constant pressure environment.
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BACKGROUND OF THE INVENTION
Electrostatic copiers provided with photoconductors of the type which comprise a web of photoconductive material including a plurality of photoconductive sections connected in series with one another so as to form an endless strip-like photoconductor, have been provided with suitable means for serially feeding the photoconductive sections from the bottom of a zigzag folded stack of such sections, at a storage station, through several processing stations and then to the top of the stack.
As disclosed in U.S. Pat. No. 3,756,488 issued Sept. 4, 1973 to Van Megen et al.; at the storage station of one known copier there has been provided apparatus for storing the photoconductive sections which includes an elongated receptacle having a generally U-shaped transverse cross-section formed by a pair of oppositely disposed walls. The walls define an upper inlet opening through which processed photoconductive sections are successively fed to the top of the stack, and a lower outlet opening through which stroed photoconductive sections are successively fed from the bottom of the stack. The receptacle walls extend convergently toward one another from the inlet opening to the outlet opening so as to cause the photoconductive sections to bow upwardly within the receptacle. Thus the folds of the photoconductive sections move progressively closer to the outlet opening than the mid-portions thereof as the sections move downwardly through the receptacle. The stack of photoconductive sections is bowed upwardly within the receptacle to facilitate feeding the sections from the bottom of the stack. The photoconductor storing apparatus also includes a pair of tamping devices, slidably attached to the opposite receptacle walls, and a pair of suitably driven rocker arms arranged to altenately lift the tamping devices and allow them to fall under the influence of gravity against the opposite folds of the photoconductive sections as they are fed to the top of the stack. The tamping devices thus cooperate with the receptacle walls in guiding the folds of the photoconductive sections below the level of their respective mid-portions.
As disclosed in U.S. patent application Ser. No. 481,048, filed June 20, 1974 and respecting which confidentiallity was waived by the assignee to permit inclusion of the application in the second Trial Voluntary Protest Program of the United States Patent and Trademark Office; in the above described storing apparatus the photoconductive sections tend to resist being upwardly bowed due to the stiffness of the photoconductor. The forces exerted upwardly on the tamping devices often prevent the same from sliding as far downwardly on the receptable walls as is permitted by the rocker arms, as a result of which the tamping devices become disassociated from the rocker arms. The arms may therefore become cocked in place on the receptacle walls or situated as close to the inlet opening that they interfere with the passage of the folds of incoming photoconductive sections. To cure the problem, the aforesaid application disclosed improved storing apparatus for moving the tamping devices out of step with one another toward and away from the stack including means for resiliently interconnecting the rocker arms to the tamping devices.
In the present application there is disclosed a different arrangement of apparatus, than is disclosed in the aforesaid U.S. patent application, for curing the problem discussed in that application for promoting longevity of the photoconductor and resilient means. Accordingly:
An object of the present invention is to provide improved apparatus for storing photoconductive sections in a zig-zag folded stack in a receptacle at the storage station of an electrostatic copier.
Summary of the Invention
In a receptacle for a stack of zig-zag folded photoconductive web material having an imaging plane, conveying means for removing the web under traction via an outlet opening from the receptacle and for supplying the web material to an inlet opening of the receptacle, the receptable having guide walls arranged such that the stack is guided through the receptacle so as to cause the web portions situated in closer proximity to the outlet opening than the inlet opening to take the form of an arc which is concave-side oriented toward the outlet opening, whereby the stack is bowed; tamping assemblies respectively movably mounted an opposite guide walls for contacting the folds of the web portions of the stack; and driving means for reciprocating the respective tamping assemblies along the guide walls; the improvement comprising: means for intermittently interconnecting the driving means and tamping assemblies, said interconnecting means including means for resiliently urging the tamping assemblies into sliding engagement with the guide walls.
BRIEF DESCRIPTION OF THE DRAWINGS
As shown in the drawings, wherein like reference numerals designate like or corresponding parts throughout the several Figures:
FIG. 1 is a schematic diagram, in elevation, of an electrostatic copier including a strip-type photoconductor having a plurality of series connected photoconductive sections folded on top of one another in a zig-zag folded stack, and including prior art apparatus for storing the photoconductive sections in the stack;
FIG. 2 is a cross-sectional, right side view, in elevation, of the electrostatic copier of FIG. 1, taken substantially along the line 2--2 thereof, showing a schematic diagram of the photoconductor imaging apparatus of the copier;
FIG. 3 is an enlarged, fragmentary perspective view of the prior art photoconductor storing apparatus of FIG. 1; and,
FIG. 4 is a reduced, fragmentary left end view, in elevation of the apparatus of FIG. 3, modified in accordance with the present invention to include improved means for guiding photoconductive sections toward the fan-folded stack and improved means for intermittently resiliently urging the folds of the photoconductive sections below the respective midportions thereof during a portion of the transit time of the stack from the top to the bottom of the receptacle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, an electrostatic copier 10, of the type which may be improved in accordance with the present invention, generally includes suitable framework 12 for supporting the various components of the copier 10, including a photoconductor 14. The photoconductor 14 is made of a suitable strip of relatively stiff foldable material, having an inner surface 16 and an outer surface 18. The outer surface 18 is coated with a suitable photoconductive powder such as an oxide of zinc dispersed in a suitable binder either along or in combination with a suitable plasticizer and a suitable dye sensitizer for extending the light sensitivity of the coating. And, the photoconductor 14 is divided into a plurality of photoconductive sections 20 of suitable length for folding purposes.
To movably support the photoconductor 14 (FIG. 1) within the copier 10, the copier 10 includes a plurality of elongated rotatable idler rollers 22, about which the photoconductor 14 is suitably endlessly looped, and a plurality elongated guide rollers 24. The rollers 22 and 24 are disposed parallel to one another and suitably secured to the framework 12 so as to longitudinally extend transverse to a desired path of travel 26 of the moving photoconductor 14. In addition, the copier 10 includes a guide plate 28 and a suitably driven elongated rotatable shaft 30. The driven shaft 30 is suitably secured to the framework 12 so as to extend parallel to the respective rollers 22 and rotate in engagement with the other surface 18 of the photoconductor 14, for moving the photoconductor 14 in the aforesaid path of travel 26 from the guide plate 28 past a charging station 32, imaging station 34, developing station 36, transferring station 38 and cleaning station 40, to a storage station 42.
At the charging station 32 (FIG. 1), the copier 10 includes a suitably electrically energizeable corona charging device 44 including a pair of elongated, high-voltage, charging electrodes 46, suitably spaced from the moving photoconductor 14 and oriented relative to the same so as to longitudinally extend transverse to the photoconductor's path of travel 26, for depositing a uniformly distributed array of electrostatic charges 48 of suitable polarity on the photoconductor's outer surface 18.
At the imaging station 34 the copier 10 includes means for providing the photoconductor 14 with information in the form of a graphic image 50 (FIG. 2) carried by a document 52 placed by the operator on a glass platen 54 secured to the copier's framework 12 beneath a cover 56. To that end, the copier 10 includes one or more electrically energizable light sources 58, mirrors 256 and 258 and a lens 60 adapted by well-known means to cooperate with one another for illuminating the document 52 and flash exposing the photoconductor 14 with light 62 modulated by the graphic-image 50. The graphic-image modulated light 62 (FIG. 1) from the mirror 258 causes the photoconductor 14 to conduct and dissipate sufficient charge 48 from the photoconductor's outer surface 18 to provide the same with a developable electrostatic latent image 64.
At the developing station 36 (FIG. 1) the copier 10 includes a container 66 for locally holding a resuable supply of developing material 68, and developer material transporting means including a suitably driven elongated rotatable shaft 72 and an elongated permanent magnet 74, magnetically coupled to one another. The magnet 74 and shaft 72 are located on opposite sides of the photoconductor 14 and suitably secured to the framework 12 so as to longitudinally extend parallel to one another, out of contact with the moving photoconductor 14 and transverse to the photoconductor's path of travel 26. The rotating shaft 72 carries developer material 68 from the container 66 into a suitably narrow space 76 between the shaft 72 and photoconductor surface 18, wherein the magnetic field 78 of the magnet 74 brings carried developer material 68 into contact with the moving photoconductor 14. As a result, some of the toner material of the carried developer material 68 adheres to the electrostatic latent image 64 so as to render the image 64 visible; thereby forming a transferable, developed image 80 on the outer surface 18 of the moving photoconductor 14.
The developed image 80 (FIG. 1) is then transferred from the photoconductor surface 18 to a suitable supporting substratum, such as a sheet of paper 82. The paper 82 is fed to the transferring station 38 from a suitably supported paper stack 84 by means of a pair of suitably driven elongated rollers 86 cooperating with an elongated idler roller 88 and a pair of guide plates 90. The rollers 86 and 88 are oriented so as to longitudinally extend parallel to one another transverse to the path of travel 26 of the moving photoconductor 14, and are suitably secured to the framework 12 for rotation in engagement with successive sheets of paper 82, to move the same from the stack 84 in a desired path of travel 92 on the guide plates 90 to the transferring station 38.
At the transferring station 38 (FIG. 1) the copier 10 includes an elongated, rotatable, idler shaft 94 suitably secured to the framework 12 so as to longitudinally extend parallel to the respective paths of travel 26 and 92 of the moving photoconductor 14 and sheet of paper 82. The rotating shaft 94 is disposed in engagement with the moving sheet of paper 82 and in sufficiently close proximity to the moving photoconductor 14 to forceably urge the paper 82 into intimate engagement with the image-bearing outer surface 18 of the moving photoconductor 14 to form a developed graphic image 96 on the sheet of paper 82. Preferably the shaft 94 is electrically energized by well-known means to provide an electric field of suitable polarity between the shaft 94 and next adjacent roller 22, tending to aid in transferring toner from the developed image 80 to the paper 82.
The graphic image 96 (FIG. 1) is thereafter fused to the paper 82 through the application of heat to the image 96. To that end, the copier 10 includes an image bonding device such as a pair of suitably heated elongated rollers 98. The rollers 98 are disposed parallel to one another and suitably secured to the framework 12 so as to longitudinally extend transverse to the path of travel 92 of the moving, image-bearing sheet of paper 82. The rollers 98 are also suitably driven by well-known means in engagement with the sheet of paper 82 for feeding the bonded-image bearing paper 82 to a receiving station 100. At the receiving station 100 the copier 10 includes a pair of suitably driven paper feeding rollers 102 adapted by well-known means to engage and feed bonded-image bearing sheets of paper 82 to a suitable hopper 104 for retrieval by the operator of the copier 10.
After the developed image 80 (FIG. 1) is transferred to a sheet of paper 82, the moving photoconductor 14 is guided to the cleaning station 40 by the idler roller 22 next adjacent to the transfer roller 94. At the cleaning station 40 the copier 10 includes a lamp 106 and a suitably housed and driven rotating brush 108. The lamp 106 is suitably secured to the copier framework 12 and disposed in sufficiently close proximity to the outer surface 18 of the photoconductor 14 to irradiate the photoconductive coating thereon in order to remove residual charge 48 from the coating. The brush 108 is suitably secured to the framework 12 so as to longitudinally extend transverse to the path of travel 26 of the moving photoconductor 14 and rotate in engagement with the same for removing any developer material 68 from the photoconductor 14 which was not transferred therefrom to the sheet of paper 82. The cleaned photoconductor 14 is thereafter fed to the storage station 42.
At the storage station 42 (FIG. 1) the copier 10 includes apparatus for temporarily storing a plurality of the photoconductive sections 20 on top of one another in a zig-zag folded stack 110. In the prior art (FIGS. 1 and 3), the storing apparatus includes an elongated, open-ended receptacle 112 having a generally U-shaped transverse cross-section. The receptacle 112 includes a pair of oppositely spaced longitudinally-extending, curved, sheet metal side walls 114, each of which has an inner side surface 116 and an outer side surface 118. The side walls 114 are suitably secured to the copier framework 12 and form an upper inlet opening 120 and a lower outlet opening 122 (FIG. 3) through which the photoconductive sections 20 are respectively fed to and from the stack 110. The side walls 114 initially extend downwardly and slightly convergently toward one another from the inlet opening 120 and then extend further downwardly and more convergently toward one another, curving through a total angle of approximately 90°, to the outlet opening 122; and then extend upwardly and convergently toward another at an angle of approximately 45° from the horizontal, to form a pair of opposed lips 124 extending inwardly of the receptacle's outlet opening 122. The wall 114 (FIG. 1) thus extend relatively convergently towards one another from the inlet opening 120 to the outlet opening 122 for guiding the folds of the stacked photoconductive sections 20 progressively closer to the outlet opening 122 than the mid-portions thereof in transit through the receptacle 112; to facilitate feeding the photoconductive sections 20 from the bottom of the stack 110 through the outlet opening 122.
To urge the opposite folds of the stacked photoconductive sections 20 (FIG. 1) toward the receptacle outlet opening 122, the storing apparatus includes a pair of oppositely-spaced tamping assemblies 126 (FIGS. 1 and 3), slidably movably mounted on opposite receptacle walls 114. The tamping assemblies 126 each include a pair of horizontally-extending rods 128 (FIG. 3) located on opposite sides of the associated receptacle wall 114, and a pair of oppositely-spaced end caps 130 fixedly secured to the adjacent ends of the associated rods 128. The attached caps 130 each includes a yoke-like body portion 132 having a slot 134 for disposition of the caps 130 of a given tamping assembly 126 in reciprocating sliding engagement with the associated receptacle wall 114. In addition, the attached caps 130 each include a head portion 135 extending outwardly from the body portion 132 in the direction of the extension of the longitudinal lengths of the associated rods 128. And, the attached caps 130 each include a pair of flange portions 138 extending laterally from the body portion 132, in opposite directions, to restrict rotation of the sliding end caps 130 on the associated walls 114, and thus prevent excessive rotation of the sliding tamping assemblies 126 relative to the associated receptacle walls 114.
The tamping assemblies 126 (FIG. 1) are moved out of step with one another, in and out of contact with the stack 110, to alternately tamp the opposite folds of the stacked photoconductive sections 20 toward the receptacle outlet opening 122. To that end, the copier storing apparatus includes a pair of oppositely spaced, suitably driven, elongated rocker arms 140 (FIGS. 1 and 3) extending across the opposite open ends of the receptacle 112 (FIG. 3). The arms 140 are suitably pivoted to the copier framework 12, approximately midway between their respective ends, and rocked in step with one another, clockwise and then counter-clockwise, above and below the horizontal and thus alternately toward and away from the stack 110 (FIG. 1) and receptacle outlet opening 122.
To facilitate feeding the stacked photoconductive sectons 20 (FIG. 1) one at a time from the bottom of the stack 110, the storing apparatus also includes a pair of elongated, oppositely-spaced, parallel rods 142 (FIG. 3) extending lengthwise through the receptacle 112. And, at each end of the receptacle 112, suitable means are provided for horizontally reciprocating the rods 142, sidewise, within the receptacle 112 including a pair of oppositely-spaced links 144, an elongated tension spring 146 and a cam 148 having an outer surface 150. At each end of the receptacle 112, the links 144 are respectively suitably pivoted to and extend from the copier framework 12 to opposite rods 142; the spring 146 is attached to and extends between the rods 142 for holding the links in bearing engagement against the outer surface 150 of the cam 148; and the suitably driven cam 148 is attached to the copier framework 12 for rotation in bearing engagement with the links 144. The cam outer surfaces 150 are respectively suitably shaped to alternately pivot the links 144 relative to the copier framework 12, to reciprocate the rods 140 toward and away from the receptacle walls 114 for alternately holding and releasing the opposite folds of the photoconductive sections 20 at the receptacle lips 124. The drive (not shown) for the cams 148 and rocker arms 140 is controlled by well-known means to ensure horizontal reciprocation of the rods 142 in timed relationship with the vertical reciprocation of the tamping assemblies 126, to synchronize the movement of the rods 142 in and out of contact with the lowermost photoconductive section 20 (FIG. 1) in the stack 110 with the movement of the tamping assemblies 126 in and out of contact with the uppermost photoconductive section 20 in the stack 110.
In a copier 10 including the above described stacking apparatus, as each photoconductive section 20 (FIG. 1) is fed from the cleaning station 40 and enters the receptacle 112 via the inlet opening 120, one of the tamping assemblies 126 is slid upwardly and the other permitted to slide downwardly on the receptacle wall 114 with which it is associated. The upwardly sliding tamping assembly 126 is thereby raised out of contact with the stack 110 to permit the leading fold of an entering photoconductive section 20, and thus the trailing fold of the previously received photoconductive section 20, to be fed beneath the upwardly sliding tamping assembly 126. On the other hand, the downwardly sliding tamping assembly 126 is permitted to fall under the influence of gravity into contact with the leading fold of the previously received photoconductive section 20 to urge the latter, and thus the trailing fold of the next previously received photoconductive section 20, into contact with the top of the stack 110. Thereafter, the rocker arms 140 raise the tamping assembly 126 previously lowered to permit the next succeeding photoconductive section 20 to be fed therebeneath, and lower the tamping assembly 126 previously raised to permit the same to slide downwardly against the leading fold of the photoconductive section 20 then disposed therebeneath. Accordingly, th rocker arms 140 play an active role insofar as raising the tamping assemblies 126 is concerned, but play a passive role insofar as tamping the photoconductive sections 20 is place on top of the stack 110 is concerned. Of course, as each successive photoconductive section 20 enters the receptacle 112 for disposition on top of the stack 110, the photoconductive section 20 then disposed at the bottom of the stack 110 is pulled over the rods 142 and receptacle lips 124, and fed out of the receptacle 112 via the outlet opening 122 for disposition on top of the guide plate 28. Thus, as the supply of photoconductor sections 20 of the stack 110 is continuously depleted, the stack 110 is replenished.
As the photoconductive sections 20 (FIG. 1) are urged toward the receptacle outlet opening 122 by the tamping assemblies 126, they tend to resist having the opposite folds thereof progressively urged closer to the receptacle outlet opening 122 than the respective mid-portions thereof. The folds thus exert an upwardly directed force on the tamping assemblies 126 and follow the upward movement of the same, thereby preventing the tamping assemblies 126 from sliding as far down on the receptacle walls 114 as is permitted by the downwardly moving rocker arms 140. When the tamping assemblies 126 are thus disassociated from the rocker arms 140 they may become cocked in place on the receptacle walls 114 above the usual level of disposition of the topmost photoconductive section 20 in the stack 110. Or, after relatively few oscillations of the rocker arms 140, the tamping assemblies 126 may become supported by a few of the photoconductive sections 20 above the lowermost level to which the rocker arms 140 permit the same to fall; as a result of which the tamping asemblies 126 are no longer raised by the rocker arms 140 a sufficient distance to permit the tamping assemblies 126 to significantly tamp the photoconductive sections 20. In at least the latter case the tamping assemblies 126 may interfere with the passage of the folds of the incoming photoconductive sections 20 to the top of the stack 110 and/or permit the photoconductive sections 20 to become stacked on top of either or both of the tamping assemblies 126; as a result of which several of the photoconductive sections 20 may be repeatedly lowered against the mid-portion of the stack 110 or otherwise unevenly distributed over the top of the stack. Eventually, such shifts in the disposition of the weight of the photoconductive sections 20 within the receptacle 112 have resulted in the mid-portion of the stack 110 collapsing, mid-portion-first downwardly, toward the receptacle outlet opening 122.
In accordance with the present invention, there are provided two pairs of carriers 200 (FIG. 4). Each of the carriers is substantially L-shaped. And, each of the carriers 200 of a given pair is spaced apart from the other and adapted for association with the opposite end caps 130 of a given tamping assembly 126. One of the legs of each of the carriers 200, of a given pair of carriers 200, is hinged at spaced points 201 to a given rocker arm 140. And the other leg is connected to the associated rocker arm 140 by means of a tension spring 202. Thus, each of the rocker arms 140 is associated with a pair of carriers 200, each of which is urged by a spring 202 toward the arm 140 associated therewith. In addition, the spring loaded leg of each of the carriers 200 forms, together with the associated rocker arm 140, a jaw which, during only a portion of the downward movement of the rocker arm 140 on the receptacle wall 114, slides over and engages the end cap 130 of the associated tamping bar assembly 126 and conveys the same toward the stack 110 under tension of the associated spring 202.
In accordance with the present invention, to cure this problem of damaging the photoconductive coating on the outer surface 18 of the respective photoconductive sections and thereby promote longevity of the photoconductor 14; there is provided a pair of spaced apart strips 160A and 160B (FIG. 4) of substantially L-shaped or straight cross-section. The strips 160A and 160B (FIG. 4) respectively include a single leg 162C for attachment of the strip to the tamping rod 128 and, the strips 160A and 160B (FIG. 4) are spaced apart from one another a distance such that they are disposed outside of the imaging plane of the photoconductor sections 20 so as to not degrade the portion of the photoconductive surface 18 of the same which is imaged at the imaging station 34 (FIG. 1).
In accordance with the objects of the invention there has been described an electrostatic copier including improved means for storing photoconductive sections in a zig-zag folded stack at the storage station of the copier.
Inasmuch as certain changes may be made in the above described invention without departing from the spirit and scope of the same, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted in an illustrative rather than limiting sense. And, it is intended that the following claims be interpreted to cover all the generic and specific features of the invention herein described.
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In a copier including a photoconductor comprising a web of photoconductive material, having a plurality of photoconductive sections connected in series with one another to form an endless strip-type photoconductor, and including suitable instrumentalities for successively feeding the photoconductive sections from a zigzag folded stack of such sections through several processing stations and back to the stack, there is provided apparatus for storing the photoconductive sections in the stack. The storing apparatus includes a receptacle having oppositely disposed walls defining an inlet opening and an outlet opening. The walls relatively converge towards one another from the inlet opening to the outlet opening, for guiding the folds of the photoconductive sections progressively closer to the outlet opening than the mid-portions thereof in transit through the receptacle. A pair of tamping devices, movably mounted on the opposite receptacle walls, cooperate with the receptacle walls for guiding incoming photoconductive sections toward the stack. In addition, apparatus is provided for moving the tamping devices out of step with one another toward and away from the stack, including for example, a pair of pivotally mounted and spring-loaded carriers adapted to slidaly engage the tamping devices during only a portion of the movement thereof so as to spring-urge each of the tamping devices into sliding engagement with the receptacle wall associated with the same during said portion of movement.
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FIELD OF THE INVENTION
[0001] This invention relates to an apparatus for melting and dispensing thermoplastic materials such as thermoplastic adhesives referred to as “hot melt” adhesives. More specifically this invention relates to a one piece melter tank which is suspended from a chassis which also serves as the housing for the entire assembly of the melting and dispensing apparatus.
BACKGROUND OF THE INVENTION
[0002] There are many known types of apparatus for converting thermoplastic or so-called “hot melt” materials from a solid state to a molten liquid state. The melted material was maintained in the molten state in the tank in sufficient volume to supply one or more applicators or dispensers. A number of design improvements were made over a period of time to provide greater efficiency of the melt tanks and reduce problems of charring or oxidation of the molten material due to the material being maintained in the molten state for a prolonged period of time.
[0003] A grid type hot melt applicator was designed to have the capability of melting a very high throughput of thermoplastic material in a very short time so that the molten material was not maintained in a molten state for prolonged periods of time which could result in degradation of the material. A typical grid type applicator is disclosed in U.S. Pat. No. 3,964,645. Other examples are shown in U.S. Pat. Nos. 3,981,416, 4,474,311, 4,667,850, and 4,821,922. Continued efforts to improve melter apparatus has resulted in the present invention.
OBJECTS OF THE INVENTION
[0004] A primary object of this invention is to provide a hot melt unit which is simple to construct and assemble and which can be produced at reduced cost to those devices of greater complexity.
[0005] Another object of this invention is to provide a low cost tank casting which does not require to of tank flanges which are needed on many of the previous designs.
[0006] Another object of the invention is to eliminate the need for providing a supporting base beneath the melt tank and manifold.
[0007] A still further object of this invention is to provide a more versatile pump/drive mounting surface.
[0008] An even further object of the invention is to provide a simplified one piece melt tank and manifold cast as an integral unit.
[0009] These and other objects of the invention will become more fully apparent from the description in the following specification and the attached drawings.
SUMMARY OF THE INVENTION
[0010] The combination of a melter tank for thermoplastic material and a supporting chassis comprising: a tank having a bottom and a plurality of sidewalls extending upwardly therefrom, forming an open topped tank, the sidewalls of the tank having upper edge portions extending around the top of the tank, heating means associated with the bottom of the tank, a chassis having a top and at least two sidewalls extending downwardly therefrom, a rigid top insulator panel to rest on the upper edge portions of the tank sidewalls, means connecting the tank to the top of the chassis with the rigid insulator panel clamped between the upper edge portions of the sidewalls and an underside of the top of the chassis to suspend the tank from the chassis.
DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of an entire assembly of a unit of melting apparatus for melting and dispensing thermoplastic material;
[0012] [0012]FIG. 2 is a perspective view of a melt tank of the invention with an integral manifold section cast in one piece with the melt tank;
[0013] [0013]FIG. 3 is a top plan view of the melt tank of FIG. 2;
[0014] [0014]FIG. 4 is a side elevational view of the melt tank of FIG. 3;
[0015] [0015]FIG. 5 is a bottom view of the tank of FIGS. 3 and 4 , with a partial cross-section of the manifold taken on line 5 - 5 of FIG. 4;
[0016] [0016]FIG. 6 is an end view of the melt tank looking at the left end of FIG. 4;
[0017] [0017]FIG. 7 is a plan view of a subassembly of pipes forming a manifold duct system;
[0018] [0018]FIG. 8 is a fragmentary cross-sectional view of a cast manifold duct system with threaded steel nipple inserts;
[0019] [0019]FIG. 9 is a perspective view of a chassis for supporting the melt tank of FIGS. 2 through 6 and showing the melt tank indicated by chain dotted lines mounted within the chassis; and
[0020] [0020]FIG. 10 is a cross sectional side view through the chassis and the melt tank with the melt tank mounted in a suspended position within the chassis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring now to the drawings and in particular to FIG. 1, a complete assembly of a melter unit for melting and dispensing thermoplastic material is indicated generally by the numeral 10 . The unit 10 has a chassis 12 which also functions as a housing for the melt tank which will be shown and described in later drawing figures. A hinged lid 14 is mounted on top of the chassis/housing 12 . A pump assembly 16 driven by an electric motor 18 is mounted on one end of the chassis 12 . A pump cover 19 rests on the top of the chassis 12 and covers the pump 16 and motor 18 .
[0022] On the opposite end of the chassis 12 is an electrical control box 20 which will not be described in further detail since it is not part of the invention.
[0023] A manifold access opening 22 is provided on one side of the chassis 12 . Extending from the opening 22 are hose ports 24 , a pressure control 26 , a drain 28 , and a filter unit 30 .
[0024] Referring now to FIGS. 2 through 6 and in particular to FIG. 2, a melt tank 32 preferably of cast aluminum has an integral manifold portion 34 cast on the bottom of the tank as best seen in FIG. 5. A manifold duct system 35 has a duct 36 which interconnects hose ports 24 , the pressure control 26 , the drain 28 and the filter unit 30 which were previously shown in FIG. 1 as projecting through an access opening 22 in the chassis 12 .
[0025] The duct system 35 can either be machined into the manifold portion 34 , or made with cast in place cored ducts and porting, or the duct system can be preformed as a subassembly of steel pipe or other suitable metal in a configuration similar to that shown in FIG. 7 and the subassembly can then be positioned in a mold (not shown)in which the melt tank is formed and the duct system can be cast in place within the manifold portion 34 at the same time the entire melt tank is cast.
[0026] If the duct system 35 uses standard cored porting in which the duct and ports are cast in place around, for example, a sand core, then internally threaded steel insert nipples 24 a , 26 a 28 a and 30 a as shown in FIG. 8 are needed to provide stronger threaded openings than would be provided by the cast material of the tank manifold 34 .
[0027] The preferred method of forming the manifold duct system 35 is to preform a subassembly of steel pipes as shown in FIG. 7 wherein a duct 36 connects ports 24 , 26 , 28 and 30 all of which are brazed or welded together to form the subassembly 35 . All the ports are internally threaded in the same manner as the steel nipple inserts 24 a , 26 a , 28 a , and 30 a shown in FIG. 8.
[0028] Using a preformed subassembly of steel pipes provides a duct system which is better able to contain the high pressure of melted liquid being pumped through the duct system and such steel pipe duct system compensates for any porosity in the tank material in manifold portion 34 .
[0029] Regardless of which method is used for forming the duct system 35 , it is important to have internally threaded steel nipples in the outlet ports to provide a positive seal with any components which may screwed into the port without the need for any O-ring seals.
[0030] Referring again to FIG. 2, the tank 32 which is of substantially rectangular shape has end walls 38 and 40 and sidewalls 42 and 44 .
[0031] A bottom 46 is inclined diagonally across the tank 44 at an angle with respect to a horizontal plane to permit drainage of molten material in the tank from the highest corner of the bottom to the lowest corner of the bottom which is indicated in FIG. 3 by a triangular low area 48 which also contains a circular pump recess 50 . The recess 50 functions as a sump or collection recess from which a pump withdraws molten material as will be explained later in further detail.
[0032] As shown in FIGS. 2 and 3, a series of fins or ribs 52 extend vertically upward from the bottom 46 and are inclined at angles to direct the flow of molten material toward the low area 48 and the pump recess 50 . As shown in FIG. 3, a sinusoidal pattern of electrical resistance heating wires 54 are embedded inside the tank bottom 46 . These wires are connected electrically in a know manner (not shown) to an electrical power source in the control box 20 . During the melting operation the wires 54 heat the tank bottom 46 and the heat passes through the fins 52 to provide heat transfer to the material in the tank.
[0033] A cast in place mounting tab 56 each having a slot 58 is positioned on each corner of the tank 32 .
[0034] The chassis 12 is shown in detail in FIG. 9 as a substantially rectangular box shaped member having sidewalls 60 and 62 formed integrally with a top 64 from heavy gauge sheet metal. A separate end wall 66 is attached to one end of the chassis and the opposite end is closed by the control box 20 shown in FIG. 1.
[0035] The top 64 has an access opening 68 which provides communication with the melt tank 32 and which is covered by the lid 14 shown in FIG. 1. A pump access hole 70 is also provided in the top 64 of the chassis 12 to receive the pump assembly 16 and to permit it to extend downwardly into the tank 32 as shown in FIG. 10.
[0036] A fixed nut 72 is attached to the chassis top 64 near each corner thereof in a position to be in alignment with one of the four mounting tabs 56 on the tank 32 . Each tab 56 receives a bolt 74 extending through one of the slots 58 and screwing into one of the nuts 72 . A plurality of “Belleville washers” 76 are positioned on each bolt 74 between the bolt head and the bottom of the respective mounting tab 56 when the bolt 74 is threaded into one of the nuts 72 and is tightened against the tab 56 . The washers 76 compensate for expansion and contraction of the bolts 74 due to changes in temperature of the bolts.
[0037] As best seen in FIG. 10, the melt tank 32 when mounted in a suspended position from the chassis top 64 clamps a rigid insulation panel 78 between the top edge 33 of the tank 32 and the chassis top 64 . The sidewalls 60 and 62 and ends of the chassis can be lined with flexible insulation panels 80 .
[0038] The chassis 12 has a removable bottom 82 and four resilient foot pads 84 located at each corner to serve as vibration dampers.
[0039] The pump assembly 16 is mounted in the opening 70 by means of a drive mount 86 attached to the chassis top 64 . The pump 16 extends downwardly to near the bottom of the pump recess 50 . In operation the pump 16 draws in molten material from the recess 50 and passes it through a drop tube 88 into the manifold portion 34 where it passes through the filter unit 30 and then to the duct 36 and to hose ports 24 . The operation of the pump 16 will not be described in further detail since the pump does not form part of the invention. For purposes of illustration a “Gerotor” type pump is shown which uses intermeshing gears to move the molten material from the recess 50 into the manifold portion 34 , however other types of pumps can also serve this function.
[0040] It should be understood that certain variations can be made in the structural details of the melt tank and the chassis and these as well as other modifications can be made in the device shown herein without departing from the scope of the invention.
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An apparatus for melting and dispensing thermoplastic materials such as thermoplastic adhesives referred to as “hot melt” adhesives. More specifically this invention relates to a one piece melter tank which is suspended from the top of a chassis which also serves as the housing for the entire assembly of the melting and dispensing apparatus.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/783,281 titled “Method of Installation of Flexible Borehole Liner Under Artesian Conditions” filed on 14 Mar. 2013, and of the filing of U.S. Provisional Patent App. Ser. No. 61/853,096 titled “Method of Installation of Flexible Borehole Liner Under Artesian Conditions” filed on 28 Mar. 2013, both the specifications of which are incorporated herein by reference. This application is related to U.S. Provisional Patent App. Ser. No. 61/793,548 entitled “Method for Sealing of a Borehole Liner in an Artesian Well” filed on 15 Mar. 2013, and the specification thereof also is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to the installation of everting flexible borehole liners into boreholes in geologic formations with shallow water tables or in geologic formations exhibiting artesian hydraulic head conditions.
Background
A “borehole” is a hole, e.g., a shaft or well, drilled into the Earth's subsurface. The hydraulic conductivity profiling techniques described in U.S. Pat. No. 6,910,374 and U.S. Pat. No. 7,281,422 have been used in over 400 boreholes since 2007. These patents, whose complete teachings are incorporated herein by reference, describe methods for determining the hydraulic transmissivity profile of the geologic formations surrounding borehole by carefully measuring the eversion of a flexible borehole liner into an open, stable, borehole. Other installations of flexible liners into boreholes, by the eversion of the liners, are disclosed in a number of other patents, such as U.S. Pat. Nos. 6,283,209, 6,794,127, and 7,896,578, obtained by this inventor. Such liners are usually installed into the open boreholes using a water level inside the liner which is significantly higher than the water table in the formation penetrated by the borehole.
However, when that required excess pressure head (difference between ambient water table level and water level supplied to the liner interior) is not available at a particular borehole, a scaffold plus an extension of the surface casing may be used to achieve the needed higher water level within the liner. In some situations of very shallow water tables, or in situations where the head within the borehole would rise above the ground surface if the surface casing were extended above the surface, the required scaffold is so high as to be very inconvenient or even dangerous, and use of scaffolds often exposes the installation personnel to freezing winter winds.
With the foregoing background, the presently disclosed invention was developed.
SUMMARY OF THE INVENTION
The invention described hereafter allows the transmissivity profiling procedure, and the installation of flexible liners used for other measurements or purposes, to be accomplished without the need for extensive scaffolding above the borehole. Furthermore, the presently disclosed apparatus and method allow the liner installation when the artesian head condition in the borehole is producing a very high rate of water flow out of the top of the borehole. Using previously known techniques, the installation of everting flexible liners into boreholes was limited to situations of less than approximately five feet of artesian head above the ground surface, even when scaffolding was employed. In contrast, the present invention greatly extends the circumstances of successful use of everting flexible liners, even to situations involving natural artesian heads twenty feet above the ground's surface. Furthermore, the method of the present disclosure allows easier installations under the more commonly encountered conditions of shallow water tables. Additional benefits will be described hereafter.
There is disclosed hereby a method and apparatus to reduce the effective water table beneath an everting flexible borehole liner, and to provide a higher pressure within the liner, in order to allow the liner eversion into the borehole, despite the existence of high artesian pressures. The method is accomplished without the extension of the borehole surface casing far above the surface to obtain the necessary driving pressure within the liner. An advantage of the presently disclosed method is that it allows the normal artesian flow out of the borehole to bypass the liner during its installation, thereby preventing the normal development of a high water pressure beneath the liner (i.e., between the descending eversion point of the liner and the bottom of the borehole). A further advantage is that in those boreholes which produce a natural gas flow to the surface, the gas is not trapped beneath the everting liner, which trapped gas hinders everting liner propagation down the borehole.
BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWING
The attached drawings, which form part of this disclosure, are as follows:
FIG. 1 is a side sectional view of a typical everting liner installation according to known techniques;
FIG. 2 is a side sectional view of three examples of water table conditions of increasing difficulties addressed according to the present invention;
FIG. 3 is a side sectional diagrammatic view of a borehole, showing the location of a bypass pipe and wellhead fixture according to the present invention, to allow the water table in the hole to be lowered and the artesian flow to be directed past the everting liner;
FIG. 4 is a side sectional diagrammatic view of a borehole similar to FIG. 3 , showing the addition of a weighty but flowable mud to the interior of the liner and the presence of selected components of the apparatus system according to the present invention;
FIG. 5 is a view similar to that seen in FIG. 4 , showing the extension of the mud-filled liner past the bypass pipe; and
FIG. 6 is a view similar to that seen in FIG. 5 , showing the further descent of the liner, with the artesian flow ascending adjacent to the liner and being removed at the wellhead fixture.
DETAILED DESCRIPTION OF THE INVENTION
An everting liner installation according to known techniques is shown in FIG. 1 . The liner 11 has been attached to the top of the casing 12 at location 13 . The liner in the borehole 14 is filled to the level 15 , which is above the water table 16 in the formation 17 . The water within the borehole 14 beneath the liner (i.e., between the bottom of the liner and the bottom of the borehole) is displaced into available flow paths in the formation 17 allowing the liner 11 to propagate by eversion of the liner at the bottom everting end of the liner. The driving pressure to evert the liner 11 is due to the difference between the head at the water level 15 in the liner and the head at the water table 16 in the formation 17 .
If the pressure head at the level 16 in the formation 17 is higher than the head at level 15 inside the liner 11 , the liner will be collapsed by the formation water pressure, and the liner cannot propagate down the borehole. A minimum pressure difference, between level 15 and level 16 , is needed to cause the liner to propagate in the eversion process. That minimum eversion pressure is greater for smaller borehole diameters than for larger diameter boreholes. For the liner 11 to be easily everted down the borehole, the water table 16 in the open borehole must be a sufficient distance below the top of the surface casing 12 to allow a water fill of the liner to drive the eversion process. For some boreholes, the minimum water table depth in the formation 17 must be at least five feet below the top of the casing 12 . In other situations of smaller boreholes, a water table 16 of at least twenty feet below the top 13 of the casing 12 may be required to supply an adequate liner driving pressure. If the water table 16 in the formation is less than the necessary depth distance below the top 13 of the casing 12 , the above-ground height of the casing 12 can be extended upward to obtain a higher water level 15 inside the liner 11 . However, there are practical safety limits as to how high the casing can be extended, with the associated surrounding scaffolding, and still allow safe working space for the installation personnel. In some situations, for safety reasons there are prohibitions against the use of any scaffolding.
FIG. 2 illustrates several static water tables as may be seen in three hypothetical boreholes 26 , 27 , 28 extending into a geologic formation 25 . In a commonly encountered circumstance, the water table level 21 is in the borehole 27 a considerable (e.g., more than about ten to fifteen feet) below the surface 29 . A more troublesome situation is when the natural water level 22 is near the surface 29 (below the top end of a casing 210 ), as seen in the middle borehole 26 of FIG. 2 . The degree of difficulty in pressure-everting a liner into such a borehole will depend somewhat upon the diameter of the borehole; generally, such a troublesome “shallow condition” involves a natural water table less than about five to about ten feet below the top end of the well casing. The more difficult situation for installing everting liners, seen in the borehole 28 on the right side of FIG. 2 , is when the level 23 of the water table in the formation intersected by the borehole 28 is above the top of the well casing, perhaps many feet above, and thus substantially above the ground's surface 29 . This is an artisan condition; in this disclosure, “artesian flow conditions” refers to the spontaneous (without artificial pumping), upward movement of water, under hydrostatic pressure in rocks or unconsolidated material beneath the earth's surface, to an elevation above the earth's surface. In this latter case, if the height of the casing were below the level 23 , the water from the subsurface formation(s) 25 would flow over the top of the surface casing (i.e., 210 in the figure) onto the surface of the ground. If the natural level 23 is very high above the surface 29 , and the transmissivity of the formation 25 is a large value, the flow rate out of the top of the (too-short) casing 210 would be large. Such flows, which can exceed 100 gal/min, normally are extremely undesirable at the borehole installation site.
In the borehole 27 seen at the left side of FIG. 2 , where the natural water level 21 is a significant distance below the surface of the ground, a typical liner installation can be effected by known techniques, as indicated in FIG. 1 . In the circumstance of the middle borehole 26 in FIG. 2 , with the water level 22 near the surface 29 , a casing extension is needed. In the third situation seen in the right borehole 28 of FIG. 2 , an everting liner installation normally would not be attempted. Whereas this invention is most useful in allowing a liner to be installed at a borehole, such as borehole 28 with an elevated artesian water level 23 see in FIG. 2 , the invention also facilitates installation in the situation of a borehole 26 with a natural water level 22 modestly above the ground's surface 29 without scaffolding or a casing extension; the method and apparatus thus is an improvement beyond currently known practices, due to safety concerns about tall scaffolding and the inconvenience of personnel working on scaffolding.
This disclosure is not a contention that it has not previously been known to use a heavy mud, in lieu of water, to pressurize and install by eversion a flexible borehole liner. Rather, the present apparatus and method are an innovative combination of processes for allowing the installation of everting liners under challenging conditions such as water levels 23 elevated many feet above the ground surface 29 such as generally described in reference to borehole 28 in FIG. 2 . Such circumstances, called artesian head conditions, normally prohibit the safe installation of everting flexible liners. Some key features of the present apparatus are the bypass pipe, the mud fill, the bulbous wellhead fixture, and the wellhead pump, all as described hereafter.
FIG. 3 shows a borehole 36 in fractured rock formation 35 with a surface casing 37 extending some depth into the fractured rock. FIG. 3 shows a partial system according to this disclosure, prior to initial completed installation. The artesian condition is shown as an upward flow 38 (directional arrows) allowing water flow over the top of the surface casing 37 above the ground's surface. A hollow wellhead fixture 39 is attached to the top of the casing 37 to support an everting liner (described further hereinafter). The fixture 39 preferably is “bulbous,” meaning that it is roughly spherical in shape to enclose an interior space, and in horizontal size (i.e. horizontal dimension or diameter) is substantially larger than the diameter of the casing 37 . The larger bulbous shape of the fixture 39 provides some working space within the fixture interior (e.g., for placing and arranging a liner preparatory to liner eversion), and the provision of a discharge outlet 311 in and on the fixture. A bypass pipe 310 of sufficient diameter to accommodate the entire artesian flow 38 is lowered into position in the borehole 36 , and situated proximate to and extending up above the top of the surface casing 37 as seen in FIG. 3 . Preferably installed, the bypass pipe 310 is intermediately overlapping between the casing 37 and an interior of the fixture 39 , with an open bottom end of the bypass pipe extending a distance into the borehole and an open top end of the bypass pipe extending into the interior of the fixture. As a result, any water flowing upward in the borehole toward the casing 37 can flow upward through the bypass pipe 310 and into the interior of the fixture 39 .
The bypass pipe 310 may be lowered, supported, and adjustably positioned with a suitable cable or other device (not shown), which supports the upper open end of the bypass pipe near a discharge outlet 311 , which may be about horizontal, on and for the bulbous wellhead fixture 39 . The vertical elevation of the bypass pipe 310 may be adjustable relative to the casing 37 and/or fixture 39 , as with a retractable cable extending from the top of the bypass pipe to a winch (not shown) at or near the fixture 39 . The bypass pipe 310 can be any conduit or tube suitable for transmitting a liquid flow, and preferably is rigid against radial collapse. As suggested by the figures, the axis of the bypass pipe 310 preferably is oriented substantially vertically, and the pipe is placed in close adjacency with, or in contact with, the casing 37 .
Referring to FIG. 4 , which shows the initial stages of installation, a pump 41 is connected with a hose 42 to be in fluid communication with the discharge outlet 43 (corresponding to outlet 311 in FIG. 3 ), of the bulbous wellhead fixture 44 (corresponding to fixture 39 in FIG. 3 ). The pump 41 has a sufficient discharge rate to draw off the water 45 rising (see directional arrows in well bore in FIGS. 3 and 4 ) under artesian pressure from the well or borehole 412 . The pumping, with the pump 41 , of water from the interior of the fixture 44 at a rate at least equaling the flow 45 of water from the borehole 412 via the bypass pipe 413 , lowers or reduces the effective water table elevation (e.g., elevation 23 in FIG. 2 ); this pumping and effective reduction in the natural water table elevation promotes the eversion of a liner into a borehole under artesian conditions, so as to allow a mud-filled liner 46 to descend to the open bottom of a bypass pipe 413 .
A flexible liner 46 is wound upon a reel 47 next to the wellhead on a short platform. The liner 46 is inside-out on the reel 47 as described in U.S. Pat. No. 7,281,422 and as shown in FIG. 1 herein. In FIG. 4 , the pump 41 is actuated to draw the water level in the bulbous wellhead fixture 44 to the level of the outlet 43 . An open-ended bypass pipe 413 is provided proximate to the borehole's surface casing (as also described in reference to FIG. 3 ). The open end of the liner 46 is then slipped over the bulbous wellhead fixture at upper location 48 and secured tightly with, e.g., a hose clamp (not shown) to the top of the wellhead fixture 44 . The liner 46 is then pushed into the wellhead fixture 44 a short distance (e.g., about arms length, approximately two to three feet) to form an annular pocket 49 as seen in FIG. 4 . A heavy water-based mud mixture such as may be confected of bentonite and powdered barite is then added, as by pouring into the annular pocket 49 , causing the liner 46 to evert past the open top end of the bypass pipe 413 . For purposes of this disclosure, the mud mixture preferably has a weight of between about 9.0 lbs/gal and about 15 lbs/gal, although these are by way of example; mud density may be customized to the conditions of the well. As indicated in FIGS. 4 and 5 , the bypass pipe preferably is between the liner and the casing, or between the liner and the wall of the borehole, as the liner descends toward the bottom of the borehole.
As indicated in FIGS. 3 and 4 , the open top end of the bypass pipe 310 , 413 preferably extends above the top of the casing and into the hollow interior of the bulbous wellhead fixture 39 , 44 that is secured atop the casing. The bypass pipe 413 of FIG. 4 is of sufficient vertical length that the heavy mud column inside the liner 46 will develop a hydrostatic pressure in the lower, everting, end 411 of the liner 46 , which pressure exceeds the artesian head in the borehole 412 when the liner 46 has propagated downward in the borehole past the bottom end of the bypass pipe 413 .
Prior to the liner everting to the open bottom end of the bypass pipe, however, the upward flow 45 in the borehole 412 is diverted, via the bypass pipe, past the everting liner 46 to the pump extraction outlet 43 in the bulbous fitting 44 . The water flowing upward in the well (i.e., flow 45 in FIG. 4 ) flows up through the bypass pipe, through the interior of the bulbous wellhead fixture 44 , and is pumped off (especially if artesian pressure is insufficient) through the outlet 43 by the action of the pump 41 . Accordingly, the liner's downward eversion is resisted little, nearly not at all, by the high pressure upward flow in the borehole 412 , until the liner 46 has reached the depth of the bottom end of the bypass pipe 413 .
As indicated by FIG. 4 , the top of the bulbous fixture 44 preferably is open, to allow the disposition of the liner 46 into the fixture interior and the addition of the heavy water-based mud 49 into the liner interior to pressure the liner interior. If desired or necessary in a very fast-flowing artesian well, a short (e.g., 3 feet to about 5 ft) casing extension may be sealably provided upon the open top of the wellhead fixture 44 to extend upward there from, and the free end of the liner attached to the top end of such casing extension, to permit the heavy-mud filled liner 46 to extend above the fixture 44 .
FIG. 5 illustrates the system after liner eversion has progressed some distance down the borehole 56 . FIG. 5 shows that when the liner 57 filled with mud 51 everts past the lower open end 52 of the bypass pipe (i.e., 413 in FIG. 4 ), the filled liner 57 , under the pressure of the contained mud 51 , presses tightly against the borehole wall below the lower end 52 of the bypass pipe. The mud-filled liner 57 thus shuts off the upward flow of water in the bypass pipe, because the mud column pressure (inside the liner 57 ) is greater than the artesian pressure in the formation 55 of FIG. 5 . At that point, the mud column 51 pressure within the liner 57 is greater than the artesian head, and the liner 57 can continue to evert further down the borehole 56 in the usual manner.
FIG. 6 shows that as the portion of the liner 611 that contains the mud 61 everts past the borehole elevation 62 at which the artesian flow enters the borehole, the corresponding artesian pressure originating at the formation 65 tends to collapse that portion of the liner 611 not sufficiently dilated with the heavy mud 61 , or without sufficient mud head 63 ( FIG. 6 ) to exceed the artesian pressure at elevation 62 . Such a situation as seen in FIG. 6 allows the artesian flow discharge to resume and to flow upward in a space 64 between the borehole wall and liner 611 to the bypass pipe 66 as the liner is everted to the bottom of the hole 67 . The above-ground flow 68 ( FIG. 6 , dashed directional line) travels from the pipe 66 (or adjacent to the pipe) to the elevation of the bulbous wellhead fixture, and then through the fixture interior and exits the fixture outlet. Note that the bulbous wellhead fixture 610 allows water rising anywhere between the upper portion of the liner 611 and the casing 612 to be collected and drawn off by the pump 69 . The discharge outlet of the bulbous wellhead fixture 610 allows the pump 69 rapidly to draw off the water that would otherwise tend to collapse the liner 611 , because the top end of the liner is sealed to the bulbous fitting 610 at location 613 . In this manner, the pump 69 can greatly reduce any tendency of the liner to be collapsed by the artesian flow above the mud-filled portion of the liner in the vicinity of elevation 62 . Use of this method and technique, including the operation of the foregoing components, including a bypass pipe 66 , a bulbous wellhead fixture 610 , a pump 69 , and weighted mud fill 61 have allowed everting liners to be installed into boreholes while performing the measurements described in U.S. Pat. No. 7,281,422, and with extreme artesian flow conditions of over 100 gallons/min., and even with artesian heads greater than 20 feet above the surface.
If the liner is a temporary liner it can be inverted from the borehole in the reverse of the procedure described above, except that the pump is still used to reduce the collapse of the liner. If the liner is to be a relatively permanent installation, the liner is filled with a weighted mud or with a grout fill. The grout fill results in an essentially permanent installation and prevents the artesian pressure collapse of the liner. The grout fill involves a special procedure to assure that the liner does not collapse as the grout is curing.
Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. The present inventive method can be practiced by employing generally conventional materials and equipment. Accordingly, the details of such materials and equipment are not set forth herein in detail. In this description, specific details are set forth, such as specific materials, structures, chemicals, processes, etc., in order to provide a thorough understanding of the present invention. However, as one having ordinary skill in the art would recognize, the present invention can be practiced without resorting strictly only to the details specifically set forth. In other instances, well known processing structures have not been described in detail, in order not to unnecessarily obscure the present invention.
Only some embodiments of the invention and but a few examples of its versatility are described in the present disclosure. It is understood that the invention is capable of use in various other combinations and is capable of changes or modifications within the scope of the inventive concept as expressed herein. Modifications of the invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.
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An apparatus and method for facilitating eversion of a flexible liner down a borehole when an artesian head condition is producing a rate of water flow out of the top of the borehole. A bypass pipe channels artesian flow, moving upward in the borehole and/or well casing, past an everting flexible liner to a wellhead fixture. Artesian flow arriving at the wellhead fixture is pumped away to ameliorate resistance to liner eversion otherwise presented by the water flow. A heavy mud may be disposed inside the everting liner further to promote its downward eversion past the artesian flow.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to an anti-electrostatic discharge spray gun apparatus and method for preventing crystallization of particles formed as a result of electrostatic discharge from forming on a spray gun nozzle and on a pair of oppositely charged electrodes disposed on the gun.
BACKGROUND OF THE INVENTION
[0002] An electrostatic air gun apparatus is well known in the art. Such an apparatus may be used in clean rooms for the manufacture of semiconductors. The apparatus normally includes a spray gun housing, a conduit for passing a fluid or gas therethrough, flow control means, a nozzle disposed between the electrodes, and a positively charged and a negatively electrode that cooperate to form an electric field and then discharge electrostatically charged particles that pass through the field. Typically, upon operation of the spray gun, a large volume of gas such as compressed air or an inert gas including but not limited to nitrogen and argon, flows through the conduit, and then through the nozzle disposed between the electrodes. Then the electrodes then discharge electrostatic ions present in the gas. However, over time, aerosol particles formed from the electrostatic discharge of the gas dispensed through the nozzle can cause a crystallized build-up of a material such as ammonium nitrate on the electrodes and the nozzle. This contamination of the electrodes and the nozzle can erode the electrodes and the nozzle, thus preventing the electrodes from performing their anti-electrostatic discharge function and preventing the nozzle from dispensing the gas.
[0003] The present invention provides a new deionized air gun that avoids crystallization from forming on the electrodes and the nozzle.
[0004] It is therefore an object of the present invention to provide an apparatus for preventing particle build up on the electrodes in an electrostatic air gun that does not have the drawbacks or shortcomings of the conventional electrostatic air guns.
[0005] It is another object of the present invention to provide a method for preventing or reducing particle build up on the electrodes that utilizes a steady flow of compressed air or an inert gas such as nitrogen to prevent crystallization of the electrodes.
[0006] It is a further object of the present invention to provide an apparatus that will not erode electrodes or a nozzle of an electrostatic spray gun.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, an apparatus and method for preventing electrostatic discharge from contaminating a nozzle and an electrostatic discharge-dissipating device are provided.
[0008] In a preferred embodiment, an anti-electrostatic discharge spray gun apparatus for preventing electrostatic discharge from causing crystallization of the nozzle has:
[0009] (a) a housing;
[0010] (b) a nozzle attached to the housing having an orifice for dispensing gas;
[0011] (c) means for dispensing a gas through the nozzle;
[0012] (d) means for electrostatically discharging a gas dispensed through the nozzle; and
[0013] (e) means for restricting the flow of a gas through the nozzle.
[0014] The anti-electrostatic discharge spray gun is further directed to a hose in communication with a gas flow source and in further communication with the nozzle; a handle movably attached to the housing, wherein the handle is capable of moving between a first position and a second position wherein the handle is normally biased in the first position; and a trigger valve in communication with the hose wherein the hose, handle and trigger valve cooperate to define the means for dispensing a gas through the nozzle.
[0015] Additionally, the present invention is further directed to a bypass piping that operates to provide a constant but low volume flow of gas through the nozzle. The bypass piping further defines the means for restricting the flow of a gas through the nozzle.
[0016] In an alternative embodiment, the present invention is directed to a stopper that defines the means for dispensing gas through the nozzle and the means for restricting the flow of a gas through the nozzle. The stopper is disposed between the handle and the trigger valve that is in communication with the hose and cooperates with the handle and the trigger valve to provide a steady but low volume flow of gas through the nozzle.
[0017] Preferably, the means for electrostatically discharging a gas dispensed through the nozzle is a pair of charged electrodes, each having an opposite polarity that cooperate to form an electric field for discharging ions present in the gas dispensed through the nozzle.
[0018] Additionally, a method of using the anti-electrostatic discharge apparatus is disclosed herein. The method provides for a steady flow of an inert gas to flow through the nozzle to prevent contamination, resulting from electrostatic discharge, of the electrodes and the nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects, features and advantages of the present invention will become apparent from the following detailed description and the appended drawings in which:
[0020] [0020]FIG. 1 is an elevational view of an electrostatic spray gun having a bypass piping in accordance with a preferred embodiment of the present invention.
[0021] [0021]FIG. 2 is an elevational view of an electrostatic spray gun having a stopper in accordance with a preferred embodiment of the present invention.
[0022] [0022]FIG. 3 is an enlarged view of a stopper and a portion of a trigger valve in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring now generally to the drawings, FIG. 1- 3 , the present invention discloses an electrostatic discharge spray gun apparatus having a nozzle; means for dispensing and means for restricting flow of a gas through a nozzle; and means for electrostatically discharging ions in a gas to prevent contamination of the nozzle caused by a crystallization buildup byproduct of an electrostatic discharge process.
[0024] As shown in a preferred embodiment in FIGS. 1 , the electrostatic discharge spray gun is further directed to an electrostatic discharge spray gun apparatus 10 , 110 having a housing 12 , 112 ; a nozzle 14 , 114 attached to the housing; means for dispensing a gas through the nozzle; means for electrostatically discharging a gas dispensed through the nozzle; and means for restricting the flow of a gas through the nozzle.
[0025] Preferably, a gas 36 , 136 dispensed through the spray gun is dry compressed air or an inert gas such as nitrogen. The housing 12 , 112 may be made from any durable material such as but not limited to metal or a high impact styrene material. The nozzle 14 , 114 may be integrally formed with the housing or may be releasably and sealably attached to the housing 12 , 112 . The nozzle 14 , 114 has an orifice 16 , 116 disposed therethrough for dispensing the gas 36 , 136 from the means for dispensing a gas through the nozzle to the atmosphere.
[0026] In a preferred embodiment as shown in FIG. 1, the means for dispensing gas through the nozzle 14 includes a hose 18 , a handle 20 , and a trigger valve 22 . Preferably, the hose 18 has a uniform diameter D having a first end 38 in communication with a gas flow source (not shown) and a second end 40 in communication with the nozzle 14 . The hose may be formed from any flexible material such as polyurethane Durometer or plastic.
[0027] Preferably, the handle 20 is disposed on the housing and is moved in a reciprocating manner between a first and a second position. The handle may be made from a durable material such as a high impact styrene material that is injection molded.
[0028] The handle 20 is movably attached to the housing 12 by a conventional fastening means well-known in the mechanical arts and moves between a first position and a second position. The handle 12 is normally biased by a biasing means in the first position, but in operation, is moved to the second position to dispense a large volume of gas through the hose 18 .
[0029] The trigger valve 22 is disposed within the housing and is in communication with the hose 18 . The trigger valve 22 is preferably, a conventional valve well known in the pneumatic arts formed from a material such as nylon that is closed when the handle 20 is in the first position and is completely opened when the handle is in the second position. The handle 20 and the trigger valve 22 cooperate to dispense the gas 36 through the hose 18 by moving the handle 18 to the first position to close the trigger valve 22 and to the second position to open the trigger valve. Thus, when the trigger valve 22 is closed, the gas 36 is prevented from passing through the hose 18 and when the trigger valve 22 is open, a large volume of the gas 36 flows through the hose 18 from a gas source and then through the nozzle 14 .
[0030] In a preferred embodiment as shown in FIG. 1, the means for dispensing a gas through the nozzle further has a bypass piping 24 in communication with the hose 18 and in further communication with the nozzle 14 for dispensing gas through the nozzle 14 when the trigger valve 22 is in a closed position. The bypass piping 24 has a uniform diameter less than the diameter D of the hose and allows a restricted flow of gas to flow through the bypass piping 24 and then through the nozzle 14 . The bypass piping 24 further has means for restricting the flow of a gas through the nozzle. The means for restricting the flow of gas through the nozzle preferably has a flow control niddle valve 26 that is capable of being adjusted to allow either a maximum amount of restricted gas to flow through the bypass piping 24 or to prevent gas from flowing through the bypass piping 24 . However, the flow control means is not limited to the niddle valve 26 but may be other conventional means for controlling flow of gas well known in the mechanical and pneumatic arts. The smaller diameter of the piping also cooperates to prevent a large volume of gas to flow through the bypass piping 24 when the niddle valve 26 is open.
[0031] Additionally, the bypass piping 24 further has a first end 42 disposed between the hose first end 38 and the trigger valve 22 in communication with the hose 18 and a second end 44 disposed between the trigger valve 22 and the hose second end 40 in further communication with the hose 18 . The flow control niddle valve 26 is disposed between the first end 42 and the second end 44 of the bypass piping 24 . The niddle valve 26 provides a restricted flow of gas through the bypass piping 24 when the niddle valve 26 is in an open position and stops a flow of gas through the bypass piping 24 when the niddle valve 26 is in a closed position. In operation, the niddle valve 26 is biased in an open position to allow a steady flow of gas 36 to flow through the bypass piping 24 and then through the nozzle 14 .
[0032] The first end 42 of the bypass piping 24 is preferably, connected to the hose 18 by a first tee-shaped connector 28 , and the second end 44 of the bypass piping 24 is preferably, connected to the hose 18 by a second tee-shaped connector 30 . However, in an alternative embodiment, the first end 42 of the bypass piping 24 may be connected directly to the nozzle 14 and the second end 44 may be connected directly to a gas source (not shown).
[0033] The electrostatic discharge spray gun 10 further has a positively charged electrode 32 preferably having a first pointed tip; and a negatively charged electrode 34 preferably having a pointed tip. Each electrode 32 , 34 , respectively, is connected to a charging source (not shown). The charged electrodes 32 , 34 define the means for electrostatically discharging gas dispensed through the nozzle 14 . The electrodes 32 , 34 preferably surround the nozzle 14 , thus the nozzle 14 is disposed between the two electrodes 32 , 34 . In operation, an electric field is formed between the charged electrodes that operate to deionized ions dispensed through the orifice 16 in the nozzle 14 and then through the electric field.
[0034] According to the preferred embodiment shown in FIG. 1, in operation, the handle 20 is biased normally in the first position and accordingly, the trigger valve 22 is biased in a closed position to prevent gas from flowing through the hose 18 when the handle 20 is in the first position. As the handle 20 moves from the first position to the second position, the gas 36 flows from the fluid source through the hose 18 . When the handle 20 is moved to the second position, the handle 20 completely engages and opens the trigger valve 22 , thus, allowing an unrestricted flow of high volume of gas to flow through the hose 18 . After the gas 36 is dispensed through the hose 18 , the handle 20 returns to the first position and thus, causes the trigger valve 22 to close.
[0035] The gas 36 dispensed through the hose 18 may become ionized while passing through the hose 18 but before being dispensed through the orifice 16 in the nozzle 14 . The gas 36 is deionized after being dispensed through the nozzle 14 and passed through the electric field.
[0036] The bypass piping 24 flow control niddle valve 26 is normally biased in an open position to allow a restricted flow of low volume of gas to flow through the bypass piping 24 at a constant rate. The operation of the flow control niddle valve 26 is preferably, independent of the trigger valve 22 such that gas flows through the bypass piping 24 when the flow control niddle valve 26 is open regardless of whether the trigger valve 22 is opened or closed. The constant flow of inert gas 36 flowing through the bypass valve 24 prevents crystallization build-up resulting from electrostatic discharge on the electrodes 32 , 34 .
[0037] In a preferred embodiment as shown in FIGS. 2 - 3 , the means for dispensing gas through a nozzle includes a hose 118 , a handle 120 , and a trigger valve 122 .
[0038] Preferably, the hose 118 has a uniform diameter D having a first end 138 in communication with a gas flow source (not shown) and a second end 140 in communication with the nozzle 114 . Preferably, the handle 120 is moved in a reciprocating manner between a first and a second position.
[0039] The handle 120 is movably attached to the housing 112 by conventional fastening means well-known in the mechanical arts and moves between a first position and a second position. The handle 120 is normally biased by a biasing means in the first position, but in operation, is moved to the second position to dispense a large volume of gas through the hose 118 .
[0040] The trigger valve 122 is disposed within the housing and is in communication with the hose 118 . The trigger valve 122 is preferably, a conventional valve well known in the pneumatic arts that is closed when the handle 120 is in the first position and is completely opened when the handle 120 is in the second position. The handle 120 and the trigger valve 122 cooperate to dispense a gas 136 through the hose 120 by moving the handle 120 to the first position to close the trigger valve 122 and to the second position to open the trigger valve 122 . Thus, when the trigger valve 122 is closed, the gas 136 is prevented from passing through the hose 118 and when the trigger valve 122 is open, a large volume of gas flows through the hose 118 from a gas source and then through the nozzle 114 .
[0041] The means for dispensing a gas through the nozzle further has a stopper 124 disposed between the handle 120 and the trigger valve 122 . The stopper 124 is preferably, a resilient member made from a material such as rubber. The stopper 124 further defines the means for dispensing a gas through the nozzle and defines the means for restricting the flow of gas through the nozzle. The stopper 124 cooperates with the handle 120 and the trigger valve 122 to provide a restricted flow of gas through the hose 118 by engaging and thus, partially opening the trigger valve 122 when the handle 120 is in the first position, and to provide an unrestricted flow of gas through the hose 118 by engaging and completely opening the trigger valve 122 when the handle 118 is in the second position. The trigger valve 122 is normally biased in a partially open position when the handle 120 is in the first position to allow a restricted flow of gas to flow through the hose 118 and then through the nozzle 114 .
[0042] The electrostatic discharge spray gun 110 further has a positively charged electrode 132 preferably having a first pointed tip; and a negatively charged electrode 134 preferably having a second pointed tip. Each electrode 132 , 134 , respectively, is connected to a charging source (not shown). The charged electrodes 132 , 134 define the means for electrostatically discharging gas dispensed through the nozzle 114 . The electrodes 132 , 134 preferably surround the nozzle 114 , thus, the nozzle 114 is disposed between the two electrodes 132 , 134 . In operation, an electric field is formed between the charged electrodes 132 , 134 , that operates to deionize ions dispensed through the orifice 116 in the nozzle 114 and then through the electric field.
[0043] In operation, the handle 120 is biased normally in the first position and accordingly, the trigger valve 122 is biased in a partially open position to allow a low volume and constant but restricted flow of gas 126 to flow through the hose 118 when the handle 120 is in the first position. As the handle 120 moves from the first position to the second position, gas flows from the fluid source through the hose 118 . When the handle 120 is moved to the second position, the handle 120 completely engages and opens the trigger valve 122 , thus, allowing an unrestricted flow of high volume of gas to flow through the hose 118 . After gas is dispensed through the hose 118 , the handle 120 returns to the first position and thus, causes the trigger valve 122 to be partially open.
[0044] Inert gas 136 dispensed through the hose 118 may become ionized while passing through the hose 118 but before being dispensed through the orifice 116 in the nozzle 114 . The gas 136 is deionized after being dispensed through the nozzle 114 and passed through the electric field.
[0045] The constant flow of inert gas flowing through the hose prevents an electrostatic discharge crystallization build-up on the tips of the electrodes and on the nozzle.
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The present invention discloses an anti-electrostatic discharge spray gun apparatus and method for preventing crystallization of particles formed as a result of electrostatic discharge from forming on a spray gun nozzle and an associated pair of oppositely charged electrodes disposed on the gun. The apparatus has a housing; a nozzle attached to the housing for dispensing gas; means for dispensing a gas through the nozzle; means for electrostatically discharging a gas dispensed through the nozzle; and means for restricting the flow of a gas through the nozzle. The means for dispensing and restricting flow of a gas through the nozzle may be either a bypass piping having a flow control means or a stopper that operates to provide a constant but low volume flow of an inert gas such as nitrogen to the nozzle to prevent particle build up or crystallization from occurring.
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BACKGROUND
[0001] Modern markets are saturated by user driven data consumption. Applications integrate media and user information from variety of sources to congregate resources in order to meet customer demand. Video and audio information consume warehouses of systems providing instantaneous access to user data across the world. User organized information require resource intensive systems to accommodate the demand. In addition, enterprise requirements complicate information storage and retrieval by inserting business requirements into the storage systems. Data reliability and analysis requirements generate additional and duplicate data for data systems already taxed with meeting user demands. Reliability requirements extend data storage by creating redundancy that consumes expensive resources.
[0002] Databases manage and provide data services to control data redundancy and reliability. Databases can generate multiple instances to meet customer rules and demand. Data retrieval through paging is a pattern in SQL. Paging allows splitting of data retrieval data to multiple pages instead of a single retrieval from the database. Each page may be requested from a different instance of the database according to business rules. Databases with multiple instances create further complexities to providing continued data retrieval services through paging while minimizing redundancy. In a database environment hosting multiple instances, a request for a next page can fail as a result of the pages being distributed across multiple servers and platforms.
SUMMARY
[0003] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to exclusively identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.
[0004] Embodiments are directed to managing data sets through page based information tracking. According to some embodiments, an application may receive a page cookie as a request for a page of records. The application may be a database store provider serving multiple instances of a data store. The application may identify retrieved pages from records by using the page cookie and date/time and data instance name/write-master information associated with the retrieved pages. The records may be queried through multiple instances of the data store. The requested page may be located by skipping the retrieved pages. Next, the application may create a new page cookie based on the page. The page cookie may have a record identifier and a timestamp for last retrieved record within the page. Subsequently, the application may transmit the new page cookie and the page to the requester.
[0005] These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. It is to be understood that both the foregoing general description and the following detailed description are explanatory and do not restrict aspects as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a networked environment, where an application may manage data sets through page based information tracking according to some embodiments;
[0007] FIG. 2 illustrates a component diagram establishing management of data sets through page based information tracking according to embodiments;
[0008] FIG. 3 illustrates an action diagram of an application managing data sets through page based information tracking according to embodiments;
[0009] FIG. 4 is a networked environment, where a system according to embodiments may be implemented;
[0010] FIG. 5 is a block diagram of an example computing operating environment, where embodiments may be implemented; and
[0011] FIG. 6 illustrates a logic flow diagram for a process managing data sets through page based information tracking according to embodiments.
DETAILED DESCRIPTION
[0012] As briefly described above, an application may manage data sets through page based information tracking. The application may receive a page cookie as a request for a page of records. The page of records may contain one or more records such as a row of data from a data table of a data store. The same data may be available in stores instances, and any of the stores instances may be used to retrieve next page. The application may identify retrieved pages from records by using the page cookie and data stamps associated with the records. The application may analyze a record identifier within the page cookie to find matching records partitioned to pages. The application may locate the page by skipping the retrieved pages. Subsequently, the application may create a new page cookie based on the identified page for transmission. The new page cookie may have a timestamp and a new record identifier marking a last retrieved record for the page. Furthermore, the application may transmit the new page cookie and the page to a requester. In the following detailed description, references are made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrations specific embodiments or examples. These aspects may be combined, other aspects may be utilized, and structural changes may be made without departing from the spirit or scope of the present disclosure. The following detailed description is therefore not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims and their equivalents.
[0013] In the following detailed description, references are made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrations specific embodiments or examples. These aspects may be combined, other aspects may be utilized, and structural changes may be made without departing from the spirit or scope of the present disclosure. The following detailed description is therefore not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims and their equivalents.
[0014] While the embodiments will be described in the general context of program modules that execute in conjunction with an application program that runs on an operating system on a computing device, those skilled in the art will recognize that aspects may also be implemented in combination with other program modules.
[0015] Generally, program modules include routines, programs, components, data structures, and other types of structures that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that embodiments may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, and comparable computing devices. Embodiments may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0016] Embodiments may be implemented as a computer-implemented process (method), a computing system, or as an article of manufacture, such as a computer program product or computer readable media. The computer program product may be a computer storage medium readable by a computer system and encoding a computer program that comprises instructions for causing a computer or computing system to perform example process(es). The computer-readable storage medium is a non-transitory computer-readable memory device. The computer-readable storage medium can for example be implemented via one or more of a volatile computer memory, a non-volatile memory, a hard drive, a flash drive, a floppy disk, or a compact disk, and comparable media.
[0017] According to embodiments, a page may contain one or more records. A record may be a row of data from a data table of a data store. The application may be a data store application managing a data store. The data store may be a database, a flat file, a spreadsheet, a data cube, or other data entity. The data store may have one or more instances running concurrently. The instances may be distributed across platforms and may each be identified by a name. Each record may have a data stamp. The data stamp may have a timestamp value and data store instance name. The data stamp may be part of the record as values in additional columns within a data table. In addition, the page cookie used to request and track transmitted pages may contain a record identifier and a timestamp of a last retrieved record within the page. A page cookie may have multiple timestamps and last retrieved record ids, one for every store instance.
[0018] Throughout this specification, the term “platform” may be a combination of software and hardware components for managing data sets through page based information tracking. Examples of platforms include, but are not limited to, a hosted service executed over a plurality of servers, an application executed on a single computing device, and comparable systems. The term “server” generally refers to a computing device executing one or more software programs typically in a networked environment. However, a server may also be implemented as a virtual server (software programs) executed on one or more computing devices viewed as a server on the network. More detail on these technologies and example operations is provided below.
[0019] Referring to FIG. 1 , diagram 100 illustrates a networked environment, where an application may manage data sets through page based information tracking according to some embodiments. The computing devices and computing environments shown in diagram 100 are for illustration purposes. Embodiments may be implemented in various local, networked, cloud-based and similar computing environments employing a variety of computing devices and systems, hardware and software.
[0020] In an example environment illustrated in diagram 100 , a client device 106 may request a page of records from data store instance(s) 102 . The client device 106 may be an end user device such as desktop computer. Alternatively, the client device may be an intermediary consumer such as a server 108 . Both client devices 106 and 108 may use network(s) 104 to communicate with the data store instance(s) 102 . A data store may have multiple instances running concurrently across multiple servers or other hardware devices. The data store instance(s) may replicate records to serve multiple requirements such as availability and data reliability. Data reliability may be ensured through back-up systems that go into service seamlessly to a client device in case of primary data store server outage.
[0021] The client device may include a variety of devices including a desktop computer, a laptop computer, a slate, a smart phone, and a server 108 . In addition, a client application executed within the client device may request the page from the data store instance(s) 102 . The client application may be a stand-alone application or it may be a client interface for the data store instance(s) 102 . In addition the client application may use an application programming interface (API) to communicate with the data store instance(s) 102 . The data store instance(s) 102 may have multiple instances as described above. In addition, the data store may provide data services within a distributed environment managing data requests to varying hardware and software components according to load requirements and organizational requirements such as compartmentalized data access.
[0022] FIG. 2 illustrates a component diagram establishing management of data sets through page based information tracking according to embodiments. Diagram 200 displays flow process for components of page request and transmission through a page cookie. The page cookie may include a timestamp and a record identifier to mark the last retrieved record from a data store. The timestamp may have date and time values to mark the time of last change applied to the record.
[0023] A client device such as server 220 may initiate a page request by transmitting a page cookie 210 to the data store. The page cookie 210 may be a container. The page cookie 210 may have a record identifier and a timestamp to identify the last retrieved record. Alternatively the page cookie may be empty to indicate that no prior pages of records were requested.
[0024] The data store 202 may receive the page cookie and analyze it against stored records. The data store, may read data stamp 204 of each record to assess whether the record belongs to retrieved pages. The data stamp 204 may have a timestamp value 206 and a data store instance name 208 . Timestamp value 206 and a data store instance name 208 may be updated together as a record of who changed the record last. The data store may identify a record through the record identifier within the page cookie 210 . In addition, the data store may compare the timestamp of the page cookie 210 and the timestamp of data stamp 204 of the record to determine the record as belonging to a retrieved page. The data store may skip the retrieved page(s) subsequent to identification. After skipping retrieved page(s), the record store may retrieve a new page 214 not previously transmitted to the client device.
[0025] According to some embodiments, a page of records may be a predetermined number of records. The number of records may be determined according to data store settings. Alternatively, the size of the page 214 may be determined dynamically according to system and organization requirements. In an example scenario, the page size may be increased or decreased according to hardware limitations such as available bandwidth. In another example scenario, the page size may be increased or decreased according to security requirements and authentication of the client device.
[0026] After locating a page 214 to be transmitted to the client, the data store may create a new page cookie 212 with information about the page 214 . The new page cookie may have a timestamp of a last retrieved record within the page 214 . The page cookie 212 may also have the record identifier of the last retrieved record. Next, the data store may fulfill the client request by transmitting the new page cookie 212 and the page 214 to the client device.
[0027] According to other embodiments, the page may include one or more records. A record may include a data stamp. The data store may read a data stamp of each record to identify the page of records to be transmitted to the client device. The data stamp may include a time stamp of a last change of a record and a data store instance name of the record. The data store may sort the records according to the timestamp value of the data stamp.
[0028] According to yet other embodiments, the data store may identify the page by selecting a subset of records matching the record identifier within the page cookie. The record identifier may be a record number allocated by the data store. The data store may compare the timestamp of the page cookie to the timestamp of the last change of the record for each record within the subset to identify the requested page. The data store may select a record with a timestamp of a last change of the record closest to the timestamp of the page cookie. The data store may select the page containing the record. Additionally, the timestamp within the cookie or a timestamp of a last change of a record within the data stamp may include a date value and a time value.
[0029] According to other embodiments, a data store may include SQL procedures to realize page cookie based retrieval of a page of records. Although not provided as a limiting example, the following may be an example pseudo code procedure to realize a page cookie:
[0000]
ALTER PROCEDURE dbo.[FindPagedSOMEDATA]
,@PageCookie
NVARCHAR(MAX) INPUT/OUTPUT
,@PageSize
INT INPUT
AS
BEGIN
-- Reading new page
SELECT TOP (SELECT @PageSize)
[SOMECOLUMNS]
FROM
[SOMETABLE] AS TBL
LEFT OUTER JOIN
@PageCookie AS PC
ON
PC.DatastoreName = TBL.ChangedDatastoreName
WHERE
PC.LastChangedDatetime IS NULL OR
PC.LastChangedDatetime < TBL.ChangedDatetime
ORDER BY
TBL.ChangedDatetime ASC
;
-- Creating new pagecookie
WITH
CTE_LastChangedDatetime(DatastoreName,
LastChangedDatetime) AS
(
SELECT
ChangedDatastoreName
,MAX(ChangedDatetime)
FROM
[NEXTPAGE]
GROUP BY
ChangedDatastoreName
),
MERGE
@tv_Cookie as PC
USING
CTE_LastChangedDatetime AS CTE
ON
PC.DatastoreName = CTE.DatastoreName
WHEN MATCHED THEN
UPDATE SET
PC.LastChangedDatetime =
CTE.LastChangedDatetime
WHEN NOT MATCHED THEN
INSERT
(DatastoreName, LastChangedDatetime)
VALUES
(nvc_DatastoreName, CTE.LastChangedDatetime)
;
END
[0030] FIG. 3 illustrates an action diagram of an application managing data sets through page based information tracking according to embodiments. Diagram 300 displays a client 310 , data store instance (DSI) 1 ( 330 ) and data store instance (DSI) 2 ( 350 ) in interaction.
[0031] An example client 310 may request a page through a page cookie 312 . In an example scenario the page cookie from request 312 may be empty in order to request the first page of the DSI 1 ( 330 ). The DSI 1 ( 330 ) may analyze the page cookie for record identifier and timestamp of the record. For an empty page cookie, the DSI 1 may retrieve an initial page 332 from the data store and create a page cookie with information about the retrieved initial page. Subsequently, the DSI 1 ( 330 ) may send the page and the page cookie 334 to the client 310 .
[0032] In a subsequent request, the client 310 may request a page 314 including record identifier and timestamp values within the page cookie. The record identifier may refer to the last retrieved record. The client may query the DSI 2 ( 350 ) for the page. The page requested may include one or more records with data stamps. The data stamps may have DSI 2 ( 350 ) as the data store instance name. The DSI 2 ( 350 ) may locate the page having the record referred in the page cookie. Subsequently, the DSI 2 ( 350 ) may retrieve the page and create a page cookie 352 with information from the page. Next, the page and page cookie may be sent 354 to the client 310 .
[0033] In a follow-up request, the client 310 may request for a refresh of a requested page 316 . The DSI 1 ( 330 ) may retrieve the page and create a page cookie ( 336 ) if there are any updates to the records within the page. The DSI 1 ( 330 ) may send the updated page and the page cookie 338 to the client 310 .
[0034] According to some embodiments, a data store may update a data stamp of a record upon detecting a change in the record. The data store may update a timestamp of a last change of a record with a current time. Additionally, the data store may update the data store instance name of the record with a current data store instance name of the record.
[0035] According to other embodiments, the data store may sort each record according to the timestamp of the last change of a record. The data store may sort the records in descending order according to the timestamp of the last change nearest to a current time value. Alternatively, the data store may sort the records in ascending order according to the timestamp of the last change furthest from the current time value. Furthermore, the data store may group each record according to a data store instance name of each record.
[0036] In yet other embodiments, the data store may detect a collision between records distributed across multiple data store instances registering differing timestamps for last change values. The data store may detect the collision by identifying records matching the same record identifier within a page cookie. The data store may resolve the conflict by selecting the record from the subset with the timestamp of the last change closest to the timestamp of the page cookie.
[0037] According to some embodiments, data stamps may be created initially and then a row inserted. Thus, a time stamp (at creation) may be defined as the time when the row is created and an instance may be defined as instance name for who inserted the row. Later, data stamps may be updated and then row(s) updated and/or inserted. Thus, a time stamp may be defined as the time when a row is updated/inserted (subsequently) and an instance may be defined as the instance name of who updated a row. As soon as a record is created, updated, or deleted, information may need to be transferred to other instances. Thus, replication from source to all destinations may be started. During replication, a record on destination (including data stamp data) may be updated to same value as in the source. After a short period of time all instances may have the same view of record including information about who updated a record and when.
[0038] The example scenarios and schemas in FIGS. 2 and 3 are shown with specific components, data types, and configurations. Embodiments are not limited to systems according to these example configurations. Managing data sets through page based information tracking may be implemented in configurations employing fewer or additional components in applications and user interfaces. Furthermore, the example schema and components shown in FIGS. 2 and 3 and their subcomponents may be implemented in a similar manner with other values using the principles described herein.
[0039] FIG. 4 is a networked environment, where a system according to embodiments may be implemented. Local and remote resources may be provided by one or more servers 414 or a single server (e.g. web server) 416 such as a hosted service. An application may communicate with client interfaces on individual computing devices such as a smart phone 413 , a laptop computer 412 , or desktop computer 411 (‘client devices’) through network(s) 410 .
[0040] As discussed above, an application may manage data sets through page based information tracking. The page cookie may have a record identifier and a timestamp of the last retrieved record. Data stamps of records in the data store may contain a timestamp of last change of the record and data store instance name. Client devices 411 - 413 may enable access to applications executed on remote server(s) (e.g. one of servers 414 ) as discussed previously. The server(s) may retrieve or store relevant data from/to data store(s) 419 directly or through database server 418 .
[0041] Network(s) 410 may comprise any topology of servers, clients, Internet service providers, and communication media. A system according to embodiments may have a static or dynamic topology. Network(s) 410 may include secure networks such as an enterprise network, an unsecure network such as a wireless open network, or the Internet. Network(s) 410 may also coordinate communication over other networks such as Public Switched Telephone Network (PSTN) or cellular networks. Furthermore, network(s) 410 may include short range wireless networks such as Bluetooth or similar ones. Network(s) 410 provide communication between the nodes described herein. By way of example, and not limitation, network(s) 410 may include wireless media such as acoustic, RF, infrared and other wireless media.
[0042] Many other configurations of computing devices, applications, data sources, and data distribution systems may be employed to manage data sets through page based information tracking. Furthermore, the networked environments discussed in FIG. 4 are for illustration purposes only. Embodiments are not limited to the example applications, modules, or processes.
[0043] FIG. 5 and the associated discussion are intended to provide a brief, general description of a suitable computing environment in which embodiments may be implemented. With reference to FIG. 5 , a block diagram of an example computing operating environment for an application according to embodiments is illustrated, such as computing device 500 . In a basic configuration, computing device 500 may include at least one processing unit 502 and system memory 504 . Computing device 500 may also include a plurality of processing units that cooperate in executing programs. Depending on the exact configuration and type of computing device, the system memory 504 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. System memory 504 typically includes an operating system 505 suitable for controlling the operation of the platform, such as the WINDOWS® operating systems from MICROSOFT CORPORATION of Redmond, Wash. The system memory 504 may also include one or more software applications such as program modules 506 , data store application 522 , and data tracking module 524 .
[0044] Data store application 522 may store records and allocate them to pages according to embodiments. The data tracking module 524 may analyze page cookies and data stamps to provide page of records. The data tracking module 524 may also manage and update timestamps, data store instance names and record identifiers. This basic configuration is illustrated in FIG. 5 by those components within dashed line 508 .
[0045] Computing device 500 may have additional features or functionality. For example, the computing device 500 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. 5 by removable storage 509 and non-removable storage 510 . Computer readable 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. Computer readable storage media is a non-transitory computer readable memory device. System memory 504 , removable storage 509 and non-removable storage 510 are all examples of computer readable storage media. Computer readable 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 500 . Any such computer readable storage media may be part of computing device 500 . Computing device 500 may also have input device(s) 512 such as keyboard, mouse, pen, voice input device, touch input device, and comparable input devices. Output device(s) 514 such as a display, speakers, printer, and other types of output devices may also be included. These devices are well known in the art and need not be discussed at length here.
[0046] Computing device 500 may also contain communication connections 516 that allow the device to communicate with other devices 518 , such as over a wireless network in a distributed computing environment, a satellite link, a cellular link, and comparable mechanisms. Other devices 518 may include computer device(s) that execute communication applications, storage servers, and comparable devices. Communication connection(s) 516 is one example of communication media. Communication media can include therein 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.
[0047] Example embodiments also include methods. These methods can be implemented in any number of ways, including the structures described in this document. One such way is by machine operations, of devices of the type described in this document.
[0048] Another optional way is for one or more of the individual operations of the methods to be performed in conjunction with one or more human operators performing some. These human operators need not be co-located with each other, but each can be only with a machine that performs a portion of the program.
[0049] FIG. 6 illustrates a logic flow diagram for a process managing data sets through page based information tracking according to embodiments. Process 600 may be implemented by a data store application in some examples.
[0050] Process 600 may begin with operation 610 where the data store may receive a page cookie as a request for a page. The page cookie may include a record identifier of last retrieved record and a timestamp of a last change of the record. At operation 620 , the data store may identify retrieved pages from records by using the page cookie and data stamps associated with the retrieved pages. Each record in the retrieved pages may have data stamps which may contain timestamps matching the timestamp in the page cookie. Next, the data store may locate the page by skipping the retrieved pages at operation 630 . The data store may create a new page cookie based on the located page at operation 640 . The new page cookie may have the record identifier of the last retrieved record of the page. Subsequently, the data store may transmit the new page cookie and the page to the requester at operation 650 .
[0051] Some embodiments may be implemented in a computing device that includes a communication module, a memory, and a processor, where the processor executes a method as described above or comparable ones in conjunction with instructions stored in the memory. Other embodiments may be implemented as a computer readable storage medium with instructions stored thereon for executing a method as described above or similar ones.
[0052] The operations included in process 600 are for illustration purposes. Managing data sets through page based information tracking may be implemented by similar processes with fewer or additional steps, as well as in different order of operations using the principles described herein.
[0053] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the embodiments. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims and embodiments.
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A data store receives a page cookie as a request for a page of records. The page cookie acts as a container to a record identifier of a last retrieved record and a timestamp of the last change to the record. The data store identifies retrieved pages to skip over according to a comparison of date, time and data instance name/write-master information for each record in the retrieved pages against the information in the page cookie. The data stamp contains information about the timestamp of last change to the record and data store instance name of the record. Subsequent to finding a matching record, the data store creates a new page cookie based on the page containing the record and transmits the new page cookie and the page to the requester.
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This invention relates to method of making a wide mouth, non-delaminating, multilayer, plastic container and the product of the method. This may be accomplished by making a multilayer preform, blowing it into a bottle, trimming off a portion of the top and curling the trimmed end. In this case, multilayer is defined as a container made from a preform that is either co-injected, sequentially molded, overmolded or other methods known in the industry. An alternative form of the invention involves the nesting of at least two plastic containers defining an open mouth and curling the material adjacent the open mouth to prevent separation of the containers at the mouth.
As used herein “curl” shall be construed to include shapes other than a circular or part circular shapes, for example, oval shapes, folded shapes, flattened rolls or combinations of these.
BACKGROUND OF THE INVENTION
Suitable materials are those that can be bi-axially oriented for packaging bottles i.e. orientable polymers, preferably heat settable such as, but not limited to, polyesters such as polyethylene terephthalate (PET), polypropylene (PP) and acrylonitrile (AN). As an example PET is used in this description. In the PET container industry, no adhesives are used to keep the different materials adhered to one another. Simple but weak molecular attraction is used to bond layers together.
Generally, plastic containers exhibit enough barrier properties (the means to inhibit the flow of gas or moisture molecules; e.g., oxygen, carbon dioxide, nitrogen, water through the walls of the container) thus protecting or preserving the product within the container so to meet specifications such as shelf life (how long the product will last before spoiling). In many cases, however, the provision of one or more a barrier layers in the container wall is necessary to guarantee adequate shelf life.
The provision of barrier layers is known in the prior art. One method used is to blow mold a container directly from a preform having one or more barrier layers between inner and outer walls. However, the barrier layers do not extend through the neck finish of the container and does not provide 100% barrier coverage in the container. This applies to both containers having a convention threaded finish as well as to wide mouth containers blown directly from wide mouth preforms. This is also true of prior art containers made by a blow and trim method in which the barrier layer(s) stop short of the trim line of the intermediate article blown from a preform. The lack of a substantially 100% barrier coverage limits the ability of the container to prevent product spoilage.
Making a wide mouth PET container by blow and trim or blow trim curl is known in the PET industry. Normally, in the prior art, the barrier coverage does not extend throughout the blown and trimmed container and the barrier layer normally stops short of the upper finish. It is also known that when a multiple layer PET bottle, including a barrier layer or layers in the wall thereof, is mechanically trimmed through the multiple layers, the layers begin to separate due to the weak bonds between layers. Once the layers start to separate, small applied forces continue the layer separation of the stiff walls into the finish and body area of the container and mechanical and visual defects result. The continued separation may resultfrom simply conveying, filling, capping, labeling, shipping the container or the like. A container being trimmed through the barrier layer(s) is preferred as this provides a container with substantially 100% coverage of the protective barrier throughout the container.
However, a container having substantially 100% barrier layer coverage involves the barrier layer(s) being open to the environment. Some barrier materials do not respond well to the exposure to certain agents such as moisture (e.g. water, steam). These barrier materials will perform poorly in that type of environment as the outside agents will follow the barrier layers downwardly throughout the entire container. This is especially true in filling of products where residual products may fall upon the top sealing surface. The net result is a container that does not meet the targeted specifications.
A last area that is a concern is that some barrier materials will prevent a good seal from being formed when using a film material to seal the container. This induction or heat seal is used frequently to provide additional barrier properties across the closure and/or provide tamper evidence (to show that the container was never previously opened). The film material is typically sealed across the top sealing portion of the container. The barrier material can inhibit a proper seal.
Trimming is well known in the plastic industry. There are many varieties of trimmers used to trim plastic containers. There are two general types of trimmers for highly oriented PET containers: the laser trim and the mechanical trim. The laser trimmer has an advantage in that it burns its way through the side walls of a PET container and cauterizes the edges of a multilayer PET container thus holding the multiple layers together. A weakness of this cauterized edge is that it is very narrow and the area immediately under the cut edge can begin separation if exposed to mechanical forces. The laser trimmer also has several disadvantages to it. A slow speed is needed to give precision cuts, smoke is emitted and an edge of material is built up.
Mechanical trimmers, however, cause separation of the multiple layers as the knife used exerts a force against the side wall of the container. As the knife penetrates each layer, the knife exerts a force on the next layer and separation of the layers occurs. Defects that the mechanical trimmer causes can be eliminated by the curling or shaping the edge of the container opening in accordance with the present invention. It has previously been revealed that curling a lip has significant advantages over a blow and trim edge (see Beck U.S. Pat. No. 6,062,408).
In a further example, the barrier termination is uneven and the trim line passes through portions of the barrier layer(s) and the monolayer of polymer.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a method of preventing delamination or separation of multiple layers of a plastic container, with or without, barrier layers at an opening thereof, at which the multiple layers are exposed. The invention provided herein provides a method and a product that eliminates the problems of layer separation by the use of a curled or shaped container lip.
SUMMARY OF THE INVENTION
According to the invention there is provided a method of preventing delamination of multiple layers of at least one polymer container having an opening defined by the multiple layers comprising the steps of:
a) providing said container having a opening defined by a perimeter at which the multiple layers are at least partially exposed;
b) heating said perimeter until workable:
c) providing a curling device; and
d) using said device to curl said perimeter sufficiently to inhibit delamination of the layers. The multiple layers may, in a preferred form, be totally exposed.
The angle of curl is preferably at least about 180° and more preferably is at least about 270° or 360°.
In a preferred form of the method, the multiple layers comprise at least inner and outer walls separated by at least one barrier layer extending throughout the container. In a further preferred form of the method, the container has been trimmed, from an intermediate blow molded article, through the at least one barrier layer to form the opening and in a more preferred form of the invention the opening has a trimmed edge forming the perimeter and said device curls the perimeter to an extent that the trimmed edge is not exposed to the environment.
In a yet further form of the method, the container comprises separate nested containers.
The invention also includes a container when made by the methods of the present invention.
BRIEF INTRODUCTION TO THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a fragmentary sectioned elevation of an open topped container showing delamination of the inner and outer plastic layers from a barrier layer;
FIG. 2 shows the open topped container of FIG. 1 with the perimeter of the open top curled through 270° to prevent delamination of the layers from the barrier;
FIG. 3 is similar to FIG. 2 with a 360° curl;
FIG. 4 is a fragmentary sectional elevation of a container having nested spaced inner and outer walls with a curled perimeter defining an opening;
FIG. 5 diagrammatically illustrates a curling die; and
FIG. 6 illustrates the method.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, a blow molded container 1 which has a 100 percent barrier layer 2 coverage between inner and outer bi-axially oriented plastic layers 3 of the container 1 illustrates the propensity for delamination of the barrier 2 and layers 3 when no provision for sealing the perimeter edge 4 of the opening 5 of the container is made. The container 1 may be blow molded, from a preform having at least one barrier layer extending only part of the height of the preform, to form an intermediate article which is then trimmed to at least partially and, preferably, completely expose the at least one barrier layer at the perimeter edge of the opening. Alternatively the barrier layer may extend throughout the preform and the blow molded container is formed directly from the preform.
As shown in FIG. 2, the perimeter edge of the opening may be sealed to prevent delamination by curling the edge about 270° into edge contact with the wall 6 of the container so that the edge is not exposed to the environment.
Increased security against delamination may be provided by increasing the edge curl to about 360° as shown in FIG. 3 . It will be appreciated the “curl”, as used herein, is intended to include other shapes which will result in the edge of the opening being brought into a sealed location such as shown, for example, in FIGS. 2 and 3 and locations intermediate these.
From the above, it will be apparent that the curl itself keeps the layers intact. The resultant bi-axial oriented container thus can have 100 percent barrier coverage which is unique in itself.
Usually a waste portion of the container is mechanically trimmed to define the opening. The waste material is ground up and the material is reused. In this case, it is helpful to minimize the amount of barrier material extending into the waste area. This is accomplished by controlling the vertical height of the barrier material in a preform such that when blown into the bi-axial oriented bottle the barrier only slightly extends beyond and above the trim mark defining the container opening.
FIG. 4 illustrates a variation of the invention in which inner 7 and outer 8 separately produced containers nested one in the other, for example, with a space 9 between them, are joined at the perimeter 10 of an opening 11 by a curl, as described above.
Referring to FIG. 5, the edge of the opening of the container end is then introduced to a curling unit 12 . This unit heats the trimmed edges of the trimmed area. This heat can be directed from an outside source such as radiation, conduction or even convection. Frictional heat can also be used or any combination.
The heating of this area of the container causes a reduction in the orientation and shrinkage in the vertical and hoop directions. In turn, the wall thickness increases and the level of crystallinity begins to increase.
This preliminary heating softens the trimmed edges so that separation due to stiffness and lack of adhesion between layers is delayed. The container edges are then curled by curling device such as curl die 13 . The softened edges then form the curl without delaminating the layers. After the curled section is cooled, the mechanical stiffness and the interlocking layers of the curl prevent separation of the edges from occurring.
The exposed edge is protected from random spills of liquid and the like.
The finish could comprise an outward roll, an inward roll or a modified flattened roll. Production of the curled finish is a function of time, temperature, pressure and tool configuration. This is accomplished once the temperature allows for workability of the edge, by feeding the edge at a predetermined rate into a curling die 13 to apply a predetermined pressure so that the flexible edge follows the form of the die and continues to loop around until the desired finish is reached. Various dies can be utilized resulting in numerous finishes.
Although curling of edges is not new, forming the curl advantageously relaxes the material's memory in the area of the curl as a result of the applied heat which anneals the material and tends to render this area amorphous and partly crystallized although not necessarily to the point where the material turns white as a result of the crystallization.
Laser trim of the edge of the opening of the container can still be used with the curl ensuring little to no separation of layers due to the additional mechanical strength of the curl.
Also the edge can be passed under a flame and the layers mechanical squeezed together. This would leave an undesirable edge. A curl would then hide the undesirable edge.
In one mode of curl would be one that extends the cut edge under itself (360° or more).
Even a curl of about 180° or less will impart sufficient resistance to delamination for certain uses.
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A method of preventing delamination of multiple layers of an oriented polymer container having an opening defined by the multiple layers comprising a bi-axially oriented multilayer polymer container having an opening defined by a perimeter at which the multiple layers are exposed; heating the perimeter until workable; providing a curling die; feeding the multilayer perimeter into the curling die to curl the perimeter sufficiently to inhibit delamination of the layers and a container when so made.
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FIELD OF THE INVENTION
The present invention relates generally to a method for preparing aluminium nitride (AlN), and more particularly to a combustion synthesis method for preparing the-powdery aluminium nitride.
BACKGROUND OF THE INVENTION
With its high thermal conductivity, a high electrical resistivity, good mechanical strength, and good oxidation and thermal-shock resistances, AlN becomes a very important ceramic material in industrial applications. It can be used for high-performance electronic substrate material, optical lenses, cutting tools, heat sinks, and many high-temperature structure materials.
The manufacturing methods for AlN include:
1) the gas phase reaction method, e.g., ##STR1## 2) the direct nitridation method, e.g., ##STR2## 3) the reduction-nitridation method, e.g., ##STR3## 4) the combustion synthesis method.
The gas reaction method is not suitable for mass production of AlN in industry because of the high cost and low productivity involved.
The direct nitridation of Al and the nitridation of powdery Al 2 O 3 methods require a process executed under a high temperature and a long period of time, e.g., 5 hours, to fully complete the reaction, which can thus result in common disadvantages including a greater energy consumption and a slow manufacturing rate.
In comparison to other methods, the combustion synthesis method is a new method used to synthesize ceramic materials by self-propagation combustion reactions. The advantages achieved thereby include those that it has a fast reaction rate, a less energy consumption and a simple manufacturing process and that it can be used for mass production. Several combustion synthesis examples were discussed in U.S. Pat. Nos. 5,453,407 and 5,460,794 which were issued to one of the present inventors and his co-workers and are owned by the same Assignee as the present invention of the present application.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide an improved method for preparing aluminium nitride of excellent synthetic characteristics. The method employs a less number of reactants and excludes an igniting agent used in the prior art processes.
In keeping with the principle of the present invention, the foregoing objective of the present invention is attained by the method for preparing aluminium nitride, which comprises the following steps:
(a) mixing an aluminium powder and an ammonium halide powder;
(b) placing the mixture in a nitrogen atmosphere; and
(c) heating the mixture to bring about a self-combustion of the mixture.
The method of the present invention further comprises a step (d), in which the combustion product obtained in the step (c) is cooled before it is ground into powder.
Preferably, step (b) of the method of the present invention is carried out in an airtight chamber filled with nitrogen gas. In addition, the mixture is placed in the airtight chamber before the nitrogen gas is introduced into the airtight chamber. The airtight chamber may be a hermetic high-pressure reactor.
The mixture of the method of the present invention contains the aluminium powder and the ammonium halide such as NH 4 Cl, NH 4 F, NH 4 Br, and NH 4 l in an appropriate ratio. The mixture may be molded into a cylindrical body under the pressure of 8-50 kg/cm 2 , preferably 8-30 kg/cm 2 . Alternatively, the mixture may be kept as a reactant in a pyrocontainer having an opening or a plurality of pores. The reactant will be referred to hereinafter as a reaction tablet hereinafter. When the process of making the reaction tablet is under way, an appropriate amount of aluminium nitride powder may be added. Said appropriate amount ranges from 1 to 30%, preferable about 10%, based on the weight of the aluminium powder and the ammonium halide powder.
The reaction tablet is then placed in a reaction chamber filled with nitrogen gas. One end of the reaction tablet is subsequently caused to bring about the combustion synthesis reaction by means of a laser or a resistance heating element capable of heating one end of the reaction tablet up to the temperature ranging between 1000° C. and 1600° C. This reaction is brought about in the presence of the nitrogen gas having pressure ranging between one and ten atmospheric pressures, preferably between one and six atmospheric pressures. The heating element includes tungsten filament or tape, and graphite filament or tape.
The method of the present invention differs from the prior art method in that the former makes use of the reaction tablet formed of aluminium powder and ammonium halide powder, and that the former employs a low nitrogen pressure under which the combustion of the reaction tablet is brought about.
Among ammonium halide, NH 4 Cl is most suitable for use in the method of the present invention. An appropriate ratio in relation to aluminium powder is in the range of 0.35-0.7:1 (in mole), preferably 0.5:1. The ammonium halide absorbs heat in its decomposition so as to slow down the melting of aluminium to maintain the porosity of the reaction tablet. In addition, a number of open channels are formed by the escape of gas which is formed in the decomposition of ammonium halide, thereby enabling the nitrogen gas to make contact with aluminium. Moreover, halogen produced in the decomposition has a catalytic effect in the nitridation reaction of aluminium in which the chemical reaction of aluminium and nitrogen is accelerated. For more details, please refer to I. A. Khan and T. R. Bhat, J. Less-Common Metals, 9, 388 (1965); A. P. Amosov, G. V. Bichurov, N. F. Bolshova, V. M. Erin, A. G. Makarenko and Y. M. Markov, Int. J. Self-Propagating Hugh-Temperature Synthesis, 1(2), 239 (1992).
In the process of making the reaction tablet, the melting of aluminium can be slowed down by an appropriate addition, such as 1-30 wt %, of a diluent like AlN which is capable of absorbing heat. In other words, the addition of the diluent helps maintain the porosity of the reaction tablet. In addition, the decrease in the combustion temperature can be attained by an addition of the diluent so as to bring about a change in the form of the product. However, the use of the diluent is suggested only if the diluent does not affect the reaction, and if the diluent does not cause the contamination of the product. For this reason, AlN is the most suitable diluent.
The pyrocontainer used in the method of the present invention is made of graphite or a ceramic material such as aluminium nitride, boron nitride, aluminium oxide, zirconium oxide, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a combustion synthesis reaction device suitable for use in the method of the present invention.
FIG. 2 shows a schematic view of heat propagation of the combustion synthesis reaction of the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of the present invention consists of a first step in which a mixture is formed of aluminium powder and ammonium halide powder in molar ratio of 1:0.35-0.7. The mixture is then molded into a reaction tablet having an appropriate form. The reaction tablet 1 is placed on a pyroplate 2 of a vacuum reactor 10, as illustrated in FIG. 1. An adjustable platform 3 is provided to facilitate the heating of the reaction tablet 1 such that the top of the reaction tablet 1 is separated from a heating wire 4 by a distance ranging between 5 and 6 mm. Thereafter, the vacuum reactor 10 is sealed off in an airtight manner. Electrodes 5 for heating and thermocouples 6 for measuring temperature are hermetically put through a wall 7 of the reactor 10 such that the electrodes 5 and the thermocouples 6 can be manipulated from the outside of the reactor 10.
The reactor 10 is then exhausted of air by means of an air exhausting system 8 so as to bring about a vacuum environment of 10 -1 Torr inside the reactor 10. A nitrogen gas supply system 9 is used to introduce the nitrogen gas of high purity into the reactor 10 until the pressure of the nitrogen gas in the reactor 10 reaches 5 atmospheric pressures. As such processes of exhausting air and introducing nitrogen gas are carried out repeatedly, both air and moisture which are adhered to the surface of powder are effectively removed. Finally, the top of the reaction tablet 1 is heated by the heating wire 4 which is supplied with electric current of several amperes via the electrodes 5.
As illustrated in FIG. 2, the heat is transmitted downwards from the heated top of the reaction tablet 1, such as from the "a" portion to the "b" portion and then on to the "c" portion. In the course of such a heat transmission as described above, the gas produced by the decomposition of ammonium halide is allowed to escape so as to form a number of open gas channels to cause the inside of the reaction tablet to be full of the nitrogen-containing material formed by the decomposition and the nitrogen gas. The heating is continued until such time when the top of the reaction tablet begins to undergo the combustion synthesis reaction. As this reaction is completed, this reaction tablet I has substantially become a powder product of aluminium nitride, which is then cooled before the pressure is reduced to one atmospheric pressure. The reactor 10 is then opened to remove therefrom the product.
The conversion rate of AlN synthesized by the method of the present invention is rather high. The residual of aluminium can be removed by acid cleaning. The production rate is about 80%, which implies that 1.2 gram of AlN is synthesized from one gram of aluminium and that the remaining 0.2 gram of aluminium is either lost or not reacted. The nature and the quantity of the impurities contained in the product are dependent on the purity of aluminium powder and the purity of ammonium halide. The evaporation of the impurities is easily brought about by the combustion heat such that the impurities contained in the product are less than the reactant. The product is mostly granular in form and is fibrous in form to less extent. The product can be easily ground into powder particles having a size less than 1 μm.
The method of the present invention may be exemplified by the following chemical equation.
Al+NH.sub.4 Cl+1/2N.sub.2 →AlN+NH.sub.3 +HCl
The following embodiments are intended to illustrate the method of the present invention and are not to be used to restrict the scopes of the present invention.
EMBODIMENTS 1-4: Different Nitrogen Gas Pressures
A mixture was formed of aluminium powder and NH 4 Cl powder in a molar ratio of 1:0.5. The mixture was then molded, under the pressure of 10 Kg/cm 2 , into a cylindrical body having a diameter of one centimeter and a height of 0.6 centimeter. The cylindrical body was then arranged in a vacuum reactor capable of withstanding high pressure. The vacuum reactor was first exhausted of air and was then filled with nitrogen gas. One end of the cylindrical body was ignited by a tungsten filament heating element for a period lasting between 45 seconds and 55 seconds. The reaction products so formed were white and powdery and were confirmed to be AlN by the XRD analysis. The reaction conditions and results are shown in the following Table 1.
TABLE 1______________________________________Embodiments Nitrogen pressure (atm) Reaction time______________________________________1 6 about 45 seconds 2* 5 about 45 seconds3 3 about 50 seconds4 1 about 55 seconds______________________________________ *a graphite heating tape was used in place of the tungsten filament heating element
EMBODIMENT 5: Addition of Diluent
A mixture was formed of aluminium powder and NH 4 Cl powder in a molar ratio of 1:0.5. A diluent of AlN powder corresponding in weight to 10% of the mixture was added to the mixture to form a cylindrical body under the molding pressure of 10 kg/cm 2 . The cylindrical body has a diameter of one centimeter and a height of 0.6 centimeter. The cylindrical body was placed in a vacuum reactor filled with nitrogen gas having a pressure of 9 atms. One end of the cylindrical body was ignited with a tungsten filament heating element for about 45 seconds. The reaction product so formed was white and powdery and was confirmed to be AlN by the XRD analysis.
EMBODIMENTS 6-11: Different Mixing Ratios and Molding Pressures
Various mixtures were formed by mixing aluminium powder and NH 4 Cl powder in various molar ratios. The mixtures were molded under various molding pressures (8-15 kg/cm 2 ) into a cylindrical body having a diameter of one centimeter and a height of 0.6 centimeter. The cylindrical body was placed in a vacuum reactor in which one end of the cylindrical body was ignited in presence of nitrogen gas (3 atm) by a tungsten filament heating element for a period lasting about 50 seconds. The reaction products were white and powdery and were confirmed to be AlN by the XRD analysis. The results are shown in the following Table 2.
TABLE 2______________________________________Embodiments Al:NH.sub.4 Cl ratio Molding pressure (kg/cm.sup.2)______________________________________ 6* 1:0.6 107 1:0.55 108 1:0.45 109 1:0.4 810 1:0.5 1211 1:0.5 15______________________________________ *a graphite heating tape was used in place of the tungsten filament heating element
EMBODIMENTS 12-14: Cylindrical Bodies of Various Sizes
The aluminium powder and the NH 4 Cl powder were mixed to form mixtures in a molar ratio of 1:0.5. The mixture was molded under the pressure of 30 kg/cm 2 to form cylindrical bodies of various sizes. The cylindrical bodies were placed respectively in a vacuum reactor filled with the nitrogen gas (3 atm). One end of the cylindrical bodies was caused to burn by a tungsten filament heating element for a period lasting between 50 seconds and 60 seconds. The reaction products were white and powdery and were confirmed to be AlN by the XRD analysis. The results are shown in the following Table 3.
TABLE 3______________________________________ Sizes of cylindrical bodiesEmbodiment (diameter × height) in centimeter______________________________________12 1 × 0.913 1.7 × 0.614 1.7 × 1.0______________________________________
EMBODIMENTS 15-17: Different Ammonium Halide
An aluminium powder and an ammonium halide powder were mixed to form a mixture in a molar ratio of 1:0.5. The mixture was molded under the pressure of 30 kg/cm 2 to form a cylindrical body having a diameter of one centimeter and a height of 0.6 centimeter. The cylindrical body was heated in a vacuum reactor containing nitrogen gas (6 atm) for a period ranging between 50 and 60 seconds by means of a tungsten filament heating element such that one end of the cylindrical body was ignited and that the combustion propagated through the whole cylindrical body. The reaction products so formed were white and powdery and were confirmed to be AlN by the XRD analysis. The results are shown in the following Table 4.
TABLE 4______________________________________Embodiments Ammonium halide______________________________________15 NH.sub.4 F16 NH.sub.4 Br17 NH.sub.4 I______________________________________
EMBODIMENT 18: Use of Container Resistant to High Temperature and Having an Opening
A mixture was formed of aluminium powder and NH 4 Cl powder in a molar ratio of 1:0.5. The mixture was placed in an aluminium nitride crucible before being placed in a vacuum reactor containing nitrogen gas (6 atm). The reaction mixture was ignited by a tungsten filament heating element for about 100 seconds. The reaction product was white and powdery and was confirmed to be AlN by the XRD analysis.
EMBODIMENT 19: Use of a Porous Container Resistant to High Temperature
A mixture was formed of aluminium powder and NH 4 Cl powder in a molar ratio of 1:0.5. The mixture was then placed in a porous crucible of graphite before being placed in a vacuum reactor containing nitrogen gas (6 atm). The reaction mixture was ignited by a tungsten filament heating element for about 90 seconds. The reaction product was white and powdery and was confirmed to be AlN by the XRD analysis.
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A method for preparing aluminium nitride includes a first step in which a mixture is formed of aluminium powder and ammonium halide powder. The mixture is then molded into a tablet, which is ignited in an airtight chamber containing nitrogen gas. Aluminium nitride is formed of the tablet through the combustion reaction of the tablet. The gas generated in the decomposition of the ammonium halide forms a number of channels in the tablet so as to enable nitrogen gas to enter the tablet to react with aluminium. The synthesis of aluminium nitride of high purity under low pressure is possible in view of the catalytic effect of the ammonium halide.
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BACKGROUND OF THE INVENTION
[0001] This invention relates in general to vehicle engines and in particular to an improved composite intake manifold assembly for use in such a vehicle engine and method for producing the same.
[0002] An intake manifold assembly of a multi-cylinder engine includes a plurality of branched air passageways or ducts. Each of the air passageways defines a generally tubular runner having an air intake port and an opposite air inlet port. The air intake port of the runner is connected to an associated plenum which supplies atmospheric, turbo, or supercharged air to the runner intake port, and the air inlet port is connected to a flange which is connected to an associated inlet port of each cylinder head of the engine to supply the air from the runner to each cylinder head. Conventional intake manifold assemblies are constructed of cast iron, magnesium, aluminum, and plastic.
[0003] A typical aluminum intake manifold assembly is produced entirely by conventional casting process. These manifolds typically include a plurality of tubes disposed having first ends connected with the outlet holes of an air intake plenum, and second opposite ends connected with the associated holes of a flange member which is adapted for mounting to a cylinder head of the engine. Since the tubes are usually U-shaped, the manifold cannot be cast in one piece but rather must be cast in two sections, with one section comprising a length of the tubing cast integrally with the plenum and the other section comprising the remaining length of the tubing cast integrally with the flange member. The halves must then be joined together with bolts and a gasket or other suitable hardware to complete the manifold, further adding to the cost and complexity of the manifold.
[0004] A typical plastic multi-piece manifold assembly includes an upper half shell and a lower half shell which are joined together by a welding process. In some instances the plastic multi-piece manifold assembly includes one or more inner shell pieces which are disposed within the upper and/or lower half shells. The inner shell can be lower partial inserts which are secured to lower half shell; upper partial inserts which are secured to the upper half shell, or both lower and upper partial inserts which are secured to the respective lower and upper half shells. The inserts are typically joined to the associated half shell by a conventional heat staking process or welding process. In some instances, a plurality of individual blow molded tubes are disposed within the upper and lower half shells and joined thereto by a conventional heat staking process. In both types of constructions, the inserts or the inserts in cooperation with upper or lower half shells define a corresponding number of runner paths through which air is supplied to the associated cylinder head of the engine.
SUMMARY OF THE INVENTION
[0005] This invention relates to an improved composite air intake manifold assembly adapted for use with an internal combustion engine and method for producing the same. The composite air intake manifold assembly includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine. The method for producing the composite air intake manifold assembly includes the steps of: (a) providing an upper half shell formed from a polymer; (b) providing a lower half shell formed from a polymer; (c) providing a one piece inner shell formed from a polymer; (d) disposing the one piece inner shell in one of the lower half shell and the upper half shell; (e) subsequent to step (d), joining the one piece inner shell to the one of the lower half shell and the upper half shell; and (f) joining the one piece inner shell to the other one of the lower half shell and the upper half shell to thereby produce the composite air intake manifold assembly, wherein the one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners, each of the runners including an opened air intake end, adapted to receive atmospheric air, and an opened air inlet end, adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine. The one piece inner shell of the air intake manifold assembly of this invention can be formed for a variety of different vehicle engine applications. As a result of this, various runner lengths and plenum volumes of the air intake manifold assembly can be attained by only modifying the one piece inner shell of the present invention.
[0006] Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of a first embodiment of a composite intake manifold assembly constructed in accordance with the present invention.
[0008] [0008]FIG. 2 is a plan view of an upper half shell used in the composite intake manifold assembly illustrated in FIG. 1.
[0009] [0009]FIG. 2A is an enlarged plan view of a portion of the upper half shell shown in FIG. 2.
[0010] [0010]FIG. 3 is a plan view of a lower half shell used in the composite intake manifold assembly illustrated in FIG. 1.
[0011] [0011]FIG. 3A is an enlarged plan view of a portion of the lower half shell shown in FIG. 3.
[0012] [0012]FIG. 4 is a perspective view of a one piece inner shell used in the composite intake-manifold assembly illustrated in FIG. 1.
[0013] [0013]FIG. 4A is an enlarged view of a portion of the one piece inner shell shown in FIG. 4.
[0014] [0014]FIG. 5 is a plan view of the one piece inner shell illustrated in FIGS. 1 and 4.
[0015] [0015]FIG. 5A is an enlarged plan view of a portion of the one piece inner shell shown in FIG. 5.
[0016] [0016]FIG. 6 is a sectional view of the composite intake manifold assembly illustrated in FIG. 1.
[0017] [0017]FIG. 7 is a sectional view of the composite intake manifold assembly taken along line 7 - 7 of FIG. 6.
[0018] [0018]FIG. 8 is a sectional view of the composite intake manifold assembly taken along line 8 - 8 of FIG. 6.
[0019] [0019]FIG. 9 is a sectional view of the composite intake manifold assembly taken along line 9 - 9 of FIG. 6.
[0020] [0020]FIG. 10 is a sectional view of the composite intake manifold assembly taken along line 10 - 10 of FIG. 6.
[0021] [0021]FIG. 11 is a sectional view of the composite intake manifold assembly taken along line 11 - 11 of FIG. 6.
[0022] [0022]FIG. 12 is a sectional view of the composite intake manifold assembly taken along line 12 - 12 of FIG. 6.
[0023] [0023]FIG. 13 is a sectional view of the composite intake manifold assembly taken along line 13 - 13 of FIG. 6.
[0024] [0024]FIG. 14 is a perspective view of an alternate embodiment of a partial inner shell which can be used in connection with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring now to the drawings, there is illustrated in FIG. 1 a perspective view of a first embodiment of a composite air intake manifold assembly, indicated generally at 10 , in accordance with the present invention. The composite intake manifold assembly 10 shown in this embodiment is for use with a V-8 engine and includes a cover 12 , an upper half shell 14 , a one piece “full” inner shell or insert 16 , and a lower half shell 18 . As will be discussed below, the cover 12 , the upper half shell 14 , the one piece inner shell 16 , and the lower half shell 18 are joined together and sealed by a suitable process to produce the composite intake manifold assembly 10 in accordance with this invention.
[0026] Preferably, the process used to form the composite intake manifold assembly 10 of this invention is a welding process. More preferably, the welding process is a linear vibration welding process. However, other suitable welding process which are operative to “heat” the surfaces causing the melting and/or fusing together of the surfaces can be used if desired. Preferably, such welding processes cause heat at the associated surfaces to create friction therebetween and cause the surfaces to be joined together by melting and/or fusing. However, welding processes which do not create friction between the adjacent surfaces but which are still effective to create heat between the surfaces to join them together can be used. For example, suitable friction welding processes can include an ultrasonic welding process, a non-linear vibration welding process, and a hot plate welding process; suitable non-friction welding processes can include laser or infrared processes. In addition, as will be discussed below, different processes can be used for the joining Of the components-of the air intake manifold assembly 10 of this invention and the sealing of the components thereof.
[0027] Preferably, the cover 12 , the upper half shell 14 , the one piece inner shell 16 , and the lower half shell 18 of the composite intake manifold assembly 10 are all formed of the same material. Such a suitable material is a glass reinforced nylon. Alternatively, other suitable materials can be used and/or the materials of one or more of the cover 12 , the upper half shell 14 , the one piece inner shell 16 , and the lower half shell 18 can be different than the others. For example, other suitable materials can include unreinforced nylon and mineral reinforced nylon. Although the composite intake manifold assembly 10 illustrated and described herein is for use with a V-8 engine application, it will be appreciated that the invention can be used in conjunction with other types of engines. For example, the composite manifold assembly can be used in connection with an inline 4 cylinder engine (I-4), an inline 6 cylinder engine (I-6), and a V-6 cylinder engine.
[0028] As shown in FIG. 1, the cover 12 is a molded cover formed from a suitable plastic material and includes a plurality of integrally molded in place vacuum taps (two of such taps illustrated in this embodiment at reference numbers 20 and 22 ). The cover 12 includes an outer peripheral edge 26 which defines an underside insertion or connecting flange 28 . Alternatively, the shape and/or the structure of the cover 12 can be other than illustrated depending upon the particular structure of the associated intake manifold assembly. The upper half shell 14 is a one piece molded half shell formed from a polymer material and includes a plenum or air intake chamber 30 and eight generally tubular shaped upper runners 32 , 34 , 36 , 38 , 40 , 42 , 44 , and 46 . Each of the runners 32 , 34 , 36 , 38 , 40 , 42 , 44 , and 46 includes a respective generally arch like inner surface 32 A, 34 A, 36 A, 38 A, 40 A, 42 A, 44 A, and 46 A, shown in FIG. 7, which defines an associated upper runner inner wall surface.
[0029] The upper half shell 14 includes a flange 48 having an opening 50 formed therein. The flange 48 is adapted to be connected to a throttle body (not shown) and the opening 50 functions as an air intake port to supply atmospheric air to the plenum 30 . The upper half shell 14 further includes an opening 52 which generally corresponds to the profile of the flange 28 of the cover 12 . The opening 52 defines a receiving flange 54 which is adapted to receive the insertion flange 28 of the cover 12 in a mating relationship therewith. Alternatively, the cover 12 could be eliminated and the upper half shell 14 could include an integrally molded cover (not shown).
[0030] The upper half shell 14 includes an outer peripheral edge 60 which defines a pair of opposed side flanges 56 and 58 and a pair of opposed end flanges 66 and 68 , best shown in FIG. 2. The side flange 56 includes five mounting holes 70 , and the side flange 58 includes five mounting holes 72 . As will be discussed below, the mounting holes 70 and 72 are adapted to receive a suitable fastener (not shown) for securing the composite intake manifold assembly 10 to a flange (not shown) of the cylinder heads (not shown) of an engine (not shown) thereby connecting each of the runners of the manifold assembly to a respective inlet of each cylinder head.
[0031] The upper half shell 14 further includes a pair of side flanges 62 and 64 which are spaced inwardly relative to side flanges 56 and 58 , respectively. As will be discussed below, the side flanges 62 and 64 and the end flanges 66 and 68 cooperate to define a continuous welding periphery or border around the edge 60 of the upper half shell 14 (partially shown in FIG. 2A by dashed line W 1 ), for securing the upper half shell 14 to the one piece inner shell 16 . The upper half shell 14 further includes a plurality of receiving flanges F 1 -F 9 , shown in FIG. 2. As will be discussed below, each of the receiving flanges F 1 -F 9 of the upper half shell 14 are adapted to receive an associated one of a plurality of insertion flanges provided on the one piece inner shell 16 .
[0032] In the illustrated embodiment, the upper half shell 14 further includes an integrally molded in place mounting bracket 80 (shown in FIGS. 6 and 12), and an integrally molded in place threaded sensor fitting connection 82 (shown in FIGS. 6 and 12). The mounting bracket 80 is adapted to secure throttle and cruise control cables (not shown) thereto. In the illustrated embodiment, the sensor fitting connection 82 is adapted to secure a charge air temperature (CAT) fitting with a turn and lock retaining feature.
[0033] The upper half shell 14 further includes eight air inlet ports 32 B, 34 B, 36 B, 38 B, 40 B, 42 B, 44 B, and 46 B. As will be discussed below, the air inlet ports 32 B, 34 B, 36 B, 38 B, 40 B, 42 B, 44 B, and 46 B are adapted to be connected to an associated inlet port of each cylinder head of the engine to supply the air from a respective one of the runners to an associated cylinder.
[0034] The lower half shell 18 is a one piece molded half shell formed from a polymer material and includes eight generally tubular shaped upper runners 132 , 134 , 136 , 138 , 140 , 142 , 144 , and 146 . Each of the runners 132 , 134 , 136 , 138 , 140 , 142 , 144 , and 146 includes a respective arch like inner surface 132 A, 134 A, 136 A, 138 A, 140 A, 142 A, 144 A, and 146 A, shown in FIG. 7, which define an associated lower runner inner wall surface.
[0035] The lower half shell 18 includes an outer peripheral edge 160 which defines a pair of opposed side flanges 162 and 164 and a pair of opposed end flanges 166 and 168 . As will be discussed below, the side flanges 162 and 164 and the end flanges 166 and 168 cooperate to define a continuous welding periphery or border around the edge 160 of the lower half shell 18 (partially shown in FIG. 3A by dashed line X 1 ), for securing the lower half shell 18 to the one piece inner shell 16 . As can be seen, in this embodiment the upper half shell welding periphery W 1 and the lower half shell welding periphery X 1 are generally the same. However, the welding peripheries W 1 and X 1 can be other than illustrated if desired. The lower half shell 18 further includes an opening 130 which is in fluid communication with the plenum 30 of the upper half shell 14 . The lower half shell 18 further includes a plurality of receiving flanges G 1 -G 9 , shown in FIG. 3. As will be discussed below, each of the flanges G 1 -G 9 of the lower half shell 18 are adapted to receive a corresponding one of a plurality of insertion flanges provided on the one piece inner shell 16 .
[0036] In the illustrated embodiment, the one piece inner shell 16 is a one piece molded shell formed from a polymer material and includes eight generally tubular shaped runner centers 232 , 234 , 236 , 238 , 240 , 242 , 244 , and 246 . As will be discussed below, the one piece inner shell runner centers 232 , 234 , 236 , 238 , 240 , 242 , 244 , and 246 in combination with the respective upper half shell runner inner wall surfaces 32 A, 34 A, 36 A, 38 A, 40 A, 42 A, 44 A, and 46 A and lower half shell runner inner wall surfaces 32 A, 34 A, 36 A, 38 A, 40 A, 42 A, 44 A, and 46 A define eight runners R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 (only one of such runners R 4 is illustrated in detail in FIG. 13), of the composite intake manifold assembly 10 . While only runner R 4 is illustrated in detail in FIG. 13, it is understood that the other runners R 1 -R 3 and R 5 -R 8 are essentially the same as runner R 4 . FIG. 8 is a partial sectional view showing runner RI, and FIG. 9 is a partial sectional view showing runner R 2 in detail.
[0037] The one piece inner shell 16 includes an outer peripheral edge 260 which defines a pair of opposed side flanges 262 and 264 and a pair of opposed end flanges 266 and 268 . The side flange 262 includes an upper side flange surface 262 A and a lower side flange surface 262 B, and the side flange 264 includes an upper side flange surface 264 A and a lower side flange surface 264 B. The end flange 266 includes an upper end flange surface 266 A and a lower end flange surface 267 B, and the end flange 268 includes an upper end flange surface 268 A and a lower end flange surface 268 B.
[0038] As will be discussed below, the upper side flange surfaces 262 A and 264 A and the upper end flange surfaces 266 A and 268 A cooperate to define a continuous welding periphery or border around an upper edge 260 of the one piece inner shell 16 (partially shown in FIGS. 3A and 4A by dashed line Y 1 ), for securing the one piece inner shell 16 to the upper half shell 114 ; and the lower side flange surfaces 262 B and 264 B and the lower end flange surfaces 266 B and 268 B cooperate to define a continuous welding periphery or border (not shown but similar to welding periphery shown by dashed line Y 1 described above) around a lower edge 260 of the one piece inner shell 16 for securing the one piece inner shell 16 to the lower half shell 18 . The one piece inner shell 16 further includes a main air collection chamber 230 which is operative to supply air from the plenum 30 to each of the runners R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 of the intake manifold assembly 10 . In FIG. 10, the main air collection chamber 230 is shown supplying air to runners R 7 and R 8 .
[0039] Each of the runner centers 232 , 234 , 236 , 238 , 240 , 242 , 244 , and 246 includes a respective air intake port, indicated generally at 232 A, 234 A, 236 A, 238 A, 240 A, 242 A, 244 A, and 246 A, and a respective air outlet port, indicated generally at 232 B, 234 B, 236 B, 238 B, 240 B, 242 B, 244 B, and 246 B. The air intake ports 232 A, 234 A, 236 A, 238 A, 240 A, 242 A, 244 A, and 246 A are in fluid communication with the main air collection chamber 230 , and the air outlet ports 232 B, 234 B, 236 B, 238 B, 240 B, 242 B, 244 B, and 246 B are in fluid communication with an associated one of the air inlet ports 32 B, 34 B, 366 B, 38 B, 40 B, 42 B, 44 B, and 46 B of the upper half shell 14 .
[0040] The one piece inner shell 16 further includes a plurality of longitudinal insertion flanges F 1 ′-F 9 ′ provided on the upper portion thereof, and a plurality of longitudinal insertion flanges G 1 ′-G 9 ′ provided on the lower portion thereof. As best shown in FIGS. 4 and 5, the insertion flange F 3 ′ is defined by a portion of an insertion flange F 3 A′ of runner center 234 and a portion of an insertion flange F 3 B′ of runner center 236 . Insertion flanges F 5 ′, F 7 ′, G 3 ′, G 5 ′, and G 7 ′ have a similar construction to that of insertion flange F 3 ′. As will be discussed below, the insertion flanges F 1 ′-F 9 ′ and G 1 ′-G 9 ′ of the one piece inner shell 16 are adapted to be received into respective receiving flanges F 1 -F 9 and G 1 -G 9 of the upper half shell 14 and the lower half shell 18 , shown in FIG. 7 and in FIG. 12. Alternatively, insertion flanges could be provided on the upper half shell 14 and the lower half shell 18 and receiving flanges adapted to receive such insertion flanges could be provided on the one piece inner shell 16 .
[0041] To assemble the components together to produce the intake manifold assembly 10 , the following process occurs. First, the cover 12 is positioned adjacent the upper half shell 14 by aligning the underside insertion flange 28 of the cover 12 with the receiving flange 54 of the upper half shell 14 . Next, a linear vibration welding process is preferably used to permanently secure the cover 12 to the upper half shell 14 . The weld used to secure the cover 12 to the upper half shell 14 is both a structural weld and a sealing flange.
[0042] Following this, the one piece inner shell 16 is properly positioned and aligned within the upper half shell 14 so that the side and end flanges 62 , 64 , 66 , and 68 of the upper half shell 14 are disposed adjacent the respective upper side and end flanges 262 A, 264 A, 266 A, and 268 A of the one piece inner shell 16 . In addition, the receiving flanges F 1 -F 9 of the upper half shell 14 and the associated insertion flanges F 1 ′ F 9 ′ of the one piece inner shell 16 are disposed in a mating and/or interlocking relationship therewith.
[0043] With the one piece inner shell 16 maintained in this position, preferably a vibration welding process is used to permanently secure the one piece inner shell 16 to the upper half shell 14 . In particular, the upper half shell 14 and the one piece inner shell 16 are welded together along their associated weld planes or joints W 1 and Y 1 to provide a structural weld to join the components together and also to provide a “sealing” connection or weld between the components (welds W 1 and Y 1 partially shown in FIG. 2A and FIGS. 4A and 5A, respectively). In addition, the upper half shell 14 and the one piece inner shell 16 are welded along the F 2 -F 9 and F 2 ′-F 9 ′, respectively, to provide a sealing weld therebetween (only welds W 2 and W 3 of the upper half shell 14 at flanges F 2 and F 3 illustrated in FIG. 2A, and only welds Y 2 and Y 3 of the insert illustrated in FIGS. 4A and 5A). As a result, each of the individual runners R 1 -R 8 in the upper half shell portion of the intake manifold assembly 10 is completely sealed off from fluid communication with an associated adjacent runner. While in this embodiment a weld is not illustrated at flanges F 1 and F 1 ′, a weld can be provided along these flanges or along any other flanges depending upon the particular structure of the associated upper half shell 14 and one piece inner shell 16 .
[0044] Next, the lower half shell 18 is properly positioned and aligned within the partially assembled air intake manifold assembly so that the side and end flanges 162 , 164 , 166 , and 168 of the lower half shell 18 are disposed adjacent the respective lower side and end flanges 262 B, 264 B, 266 B, and 268 B of the one piece inner shell 16 . In addition, the receiving flanges G 1 -G 9 of the lower half shell 18 and the associated insertion G 1 ′ G 9 ′ of the one piece inner shell 16 are disposed in a mating and/or interlocking relationship therewith.
[0045] With the lower half shell 18 maintained in this position, preferably a vibration welding process is used to permanently secure the insert lower half shell 18 to the partly assembled air intake manifold assembly and to produce the air intake manifold assembly 10 of this invention. In particular, the lower half shell 18 and the one piece inner shell 16 are welded together along their associated weld planes or joints to provide a structural weld (only weld X 1 of the lower half shell 18 illustrated in FIG. 3A) to join the components together and also to provide a “sealing” weld between the components. In addition, the lower half shell 18 and the one piece inner shell 16 are welded or otherwise connected along the flanges G 1 -G 9 and G 1 ′-G 9 ′, respectively, to provide a sealing weld therebetween (only welds X 2 , X 3 and X 4 of the lower half shell 18 at flanges G 1 , G 2 and G 3 illustrated in FIG. 2A, no welds shown for one piece inner shell 16 but are similar to those welds Y 2 and Y 3 of the one piece inner shell 16 illustrated in FIGS. 4A and 5A). As a result, each of the individual runners R 1 -R 8 in the lower half shell portion of the intake manifold assembly 10 is completely sealed off from fluid communication with an associated adjacent runner. Alternatively, if it is not desired to seal off a runner from an associated adjacent runner, or if a different type of insert is used (as will be discussed below in connection with FIG. 14), or if no insert is used at all, only the “structural” weld along the associated flanges 62 , 64 , 66 , 68 and 162 , 164 , 166 , and 168 of the upper half shell 14 and the lower half shell 18 may be needed. Also, the structure of the receiving flanges F 1 -F 9 and G 1 -G 9 of the upper half shell 14 and the lower half shell 18 , respectively, and/or the structure of the insertion flanges F 1 ′-F 9 ′ and G 1 ′-G 9 ′ of the one piece inner shell 16 can be other than illustrated if desired. If however it is desired to prevent air leakage from adjacent runners, the structure of such flanges should be such that they are in relatively close proximity with one another to allow them to be joined together to provide a seal therebetween.
[0046] As discussed above, FIG. 13 illustrates runner R 4 in detail. As shown therein, runner R 4 functions to supply air from main chamber 230 , to air inlet port 138 A, in the direction of the arrows, to air outlet port 138 B, and to air inlet port 38 B. Also, since the runner center 234 of the one piece inner shell 16 is sealed along all adjacent surfaces of the upper half shell 14 and the lower half shell 18 , all the air entering runner R 4 from port 138 A is supplied to port 38 B without any air leakage to the adjacent runners R 3 and R 5 . Thus, a “360 degree” wrap weld joint is created in runner R 4 , as well as the other runners R 1 -R 3 and R 5 -R 8 . The term 360 degree wrap weld joint as used herein refers to the fact that the associated runner is completely sealed around its entire arch shaped path from an adjacent runner, the path being defined from the air inlet port of the runner to the associated air outlet port thereof in a generally full circular path (i.e., a 360 degree like path). As a result, there is no air leakage from one runner to an adjacent runner, and the air supplied to each associated cylinder head is maintained uniform.
[0047] [0047]FIG. 14 illustrates an alternate embodiment of a partial inner shell or insert, indicated generally at 316 , which can be used in place of the one piece full inner shell 16 . The partial inner shell 316 includes flanges 318 , 320 , 322 , 324 , and 326 . The flanges 318 , 320 , 322 , 324 , and 326 are provided with respective openings 318 A, 320 A, 322 A, 324 A, and 326 A. The openings 318 A, 320 A, and 322 A are operative to enable the partial inner shell 316 to be joined to the associated upper half shell 14 or lower half shell 18 by an appropriate method, such as for example, by heat staking. The openings 324 A and 326 A are operative to enable additional inserts (not shown) to be connected to the partial inner shell 316 . The number of partial inner shells 316 which are used is dependent upon the particular vehicle application.
[0048] One advantage of the air intake manifold assembly 10 illustrated in FIGS. 1 - 13 is that the runners R 1 -R 8 are completely sealed off from fluid communication with each adjacent runner to prevent air leakage from one runner to an adjacent runner. As a result of this, the air supplied to each associated cylinder head from the air intake manifold assembly 10 of this invention is maintained at a desired generally constant flow rate. Another advantage of the air intake manifold assembly 10 illustrated in FIGS. 1 - 13 is that the one piece inner shell 16 can be formed for a variety of different vehicle engine applications. As a result of this, various runner lengths and plenum volumes can be attained by only modifying the one piece inner shell 16 of the present invention. Yet another advantage of this invention is that the one piece inner shell 16 allows a generally arch shaped runner with a greater than 180 degrees wrap. Still a further advantage of the air intake manifold assembly 10 of this invention is that a generally “straight” weld is used to connect the side flanges 62 and 162 and 64 and 164 of associated upper half shell 14 and the lower half shell 18 . This straight weld can be used with the one piece full inner shell 16 illustrated in FIGS. 1, 4, 4 A, 5 , 5 A, and 7 - 13 , the insert 316 illustrated in FIG. 14, or with no inner shell at all. In addition, a straight weld could be used to connect the side flanges 62 and 162 and 64 and 164 , and a separate structural and/or sealing weld could be used with the inner shell or inner shells. In either of the above structures, as a result of this generally straight weld, the associated “burst pressure strength” of the air intake manifold assembly 10 is increased. Thus, the air intake manifold assembly 10 of this invention can eliminate the need of providing a costly blow off safety valve. Still a further advantage of the air intake manifold assembly 10 of this invention is that the upper half shell 14 includes an integrally molded in place mounting bracket 80 , sensor fitting connection 82 , and vacuum taps 20 and 22 . As a result of this, the costs associated with the brass fitting typically used for the connection and taps can be eliminated.
[0049] In accordance with the provisions of the patents statues, the principle and mode of operation of this invention have been described and illustrated in its preferred embodiments. However, it must be understood that the invention may be practiced otherwise than as specifically explained and illustrated without departing from the scope or spirit of the attached claims.
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A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine. The method for producing the composite air intake manifold assembly includes the steps of: (a) providing an upper half shell formed from a polymer; (b) providing a lower half shell formed from a polymer; (c) providing a one piece inner shell formed from a polymer; (d) disposing the one piece inner shell in one of the lower half shell and the upper half shell; (e) subsequent to step (d), joining the one piece inner shell to the one of the lower half shell and the upper half shell; and (f) joining the one piece inner shell to the other one of the lower half shell and the upper half shell to thereby produce the composite air intake manifold assembly, wherein the one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners, each of the runners including an opened air intake end, adapted to receive atmospheric air, and an opened air inlet end, adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
This is a division, of application Ser. No. 09/759,043, filed on Jan. 12, 2001, now U.S. Pat. No. 6,544,911.
This invention is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/484,749, filed Jan. 18, 2000 by Qinyun Peng et al.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention involves a cured, siloxane containing, non-woven fiber mat containing a binder mixture which can be suitably employed as a roofing or other building composite requiring improved tear strength.
2. Description of the Prior Art
Various methods to improve mat strength and stability of non-woven fibrous mats have been devised which are described in many patents and publications, representative of which are the following.
U.S. Pat. No. 4,335,186 discloses a chemically modified asphalt composition wherein the asphalt is reacted with a nitrogen-containing organic compound capable of introducing to the asphalt functional groups which can serve as reactive sites to establish a secure chemical bond between the asphalt and reinforcing fillers blended into the asphalt, such as glass fibers and siliceous aggregates.
U.S. Pat. No. 4,430,465 discloses an article of manufacture comprising a mat of fibers, such as glass fibers, coated with a composition comprising asphalt, an alkadiene-vinylarene copolymer, a petroleum hydrocarbon resin and an anti-stripping agent of a branched organic amine.
U.S. Pat. No. 5,518,586 discloses a method of making a glass fiber mat comprising dispersing glass fibers in an aqueous medium containing hydroxyethyl cellulose to form a slurry; passing the slurry through a mat forming screen to form a wet fiber glass mat; applying a binder comprising urea-formaldehyde resin and a water-insoluble anionic phosphate ester and a fatty alcohol to the wet glass fiber mat; and curing the binder.
U.S. Pat. No. 5,744,229 discloses a glass fiber mat made with polymer-reacted asphalt binder. The binder of the glass fiber mat comprises an aqueous emulsion of polymer modified asphalt produced by reaction of asphalt, a surfactant and a phenol-, resorcinol-, urea- or melamine-formaldehyde resin.
U.S. Pat. No. 5,851,933 describes a non-woven fibrous mat comprising glass fibers bonded with a cured mixture of urea/formaldehyde resin and a self crosslinkable vinyl acrylic/polyvinyl acetate copolymers and U.S. Pat. No. 5,334,648 describes emulsion copolymers for use as a urea formaldehyde resin modifier.
U.S. Pat. No. 4,917,764 describes a glass fiber mat having improved strength featuring a carboxylated styrene-butadiene latex.
U.S. Pat. No. 5,804,254 describes a method for flexibilizing cured urea formaldehyde resin-bound glass fiber non-wovens.
U.S. Pat. No. 5,503,920 describes a process for improving parting strength of fiberglass insulation.
U.S. Pat. No. 5,032,431 describes a glass fiber insulation binder.
U.S. Pat. No. 4,931,318 describes silica as a blocking agent for fiberglass sizing.
U.S. Pat. No. 4,749,614 describes a fibrous substrate coated with a hydrolyzed amino silane useful for preparing polyepoxide substrates.
U.S. Pat. No. 4,596,737 describes a process for treating a glass fiber mat comprising contacting the surface of a cured mass of glass fibers with a latex polymer.
U.S. Pat. No. 4,500,600 describes glass fibers coated with a size composition comprising γ-aminopropyltriethoxysilane and an alkoxysilane.
PCT WO 99/13154 describes a structural mat matrix comprising a substrate of fiberglass fibers and wood pulp and a binder which consists of urea formaldehyde and acrylic copolymer.
BASF's April 1998 advertising brochure entitled NONWOVENS AND COATINGS DISPERSIONS discloses a crosslinked styrene/acrylic polymer (ACRONAL® S 886S) useful as a binder for glass substrates.
Copending U.S. patent application Ser. No. 09/484,749 discloses a fiber glass mat roofing composite, a urea/formaldehyde resin binder and a polysiloxane adhesion modifier.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided a cured, polysiloxane containing, non-woven, fibrous mat comprising from about 60 to about 95 wt. % fibers containing from about 0.001 to about 15 wt. % polysiloxane; which fibers are fixedly distributed in from about 40 to about 5 wt. % of a formaldehyde type binder containing between about 0.1 and about 20 wt. % of a crosslinked styrene/acrylic or methacrylic, designated herein as (meth)acrylic, copolymer as a binder modifier.
Although several methods of making non-woven fiber mats can be used to form the present mat, a wet laid process wherein the fibers are dispersed in white water to form a wet web derived from a slurry or mat is preferred. Optionally a dispersing agent, emulsifier, lubricant, defoamer, surfactant and/or other conventional excipients can be added to the fiber containing slurry of the present invention. In a mat forming machine such as a paper pulp apparatus, e.g. a Fourdrinier paper machine, excess water is removed from the fiber slurry to form the web and the modified binder of this invention, as a 5 to 40% aqueous solution, dispersion or emulsion is then applied to the wet web by use of a curtain coater or a dip and squeeze or knife edge applicator. Alternatively, the modified binder can be sprayed onto the wet web. Following binder saturation of the web, excess binder is removed and a web containing a siloxane polymer is then dried and cured at a temperature of between about 200°-400° C. for a period of from a few seconds to about 5 minutes. The siloxane can be introduced after or in admixture with the modified binder solution, or, if desired, a portion or all of the siloxane can be introduced into the fiber size or slurry before addition of binder. The siloxane component is employed in the form of a solution, suspension, emulsion or dispersion in water or in an organic solvent, such as isopropanol, cyclohexanol or other inert organic solvent. For the purposes of the present invention, a coating of polysiloxane or asphalt can be added as a top coat on the cured mat.
DETAILED DESCRIPTION OF THE INVENTION
The preferred cured fiber mat of the present invention comprises by weight from about 68 to about 92% fiber containing from about 0.01 to about 10% polysiloxane and from about 8 to about 32% formaldehyde type binder containing between about 0.05 and about 15% of a 0.05 to about 10% crosslinked styrene/acrylic polymer modifier.
The formaldehyde type binder base is a thermosetting resin of formaldehyde in combination with urea, phenol, resorcinol, melamine or mixtures thereof. Of these, the formaldehyde/urea binder base is preferred. The binder base contains a binder modifying amount of a styrene/acrylic resin containing a polyfunctional component which crosslinks with the copolymer resin during curing of the mat. The styrene component of the resin can be unsubstituted or substituted on a ring carbon atom with lower alkyl, vinyl, allyl, chloro or phenyl; however, from the standpoint of economics; notwithstanding the reduced flammability and high thermal stability of some of these substituted types, unsubstituted styrene is most desired. The styrene/acrylic resin, which includes both acrylic and methacrylic moieties and mixtures thereof, contains a minor amount, e.g. between about 0.05 to 10 wt. %, preferably between about 0.1 and about 5 wt. %, of a crosslinking agent which may be a nitrogen containing crosslinking agent, such as a polyfunctional amine, amide or acrylonitrile, or may be any other polyfunctional crosslinking agent such as for example a di- or tri-olefinically unsaturated hydrocarbon or other conventional crosslinker reactive with the styrene/acrylic copolymer. Of the above polymer compositions, those providing self-crosslinkable characteristics are preferred. The (meth)acrylic polymer is generally a mixture of (meth)acrylates and additionally may contain (meth)acrylonitriles, (meth)acrylic acid and/or (meth)acrylamides as comonomers. One advantage of the present modified binder is that it allows for curing at a lower temperature than would otherwise be required for a mat containing siloxane/formaldehyde type binder alone. It is believed that this benefit is attributable to the crosslinking of the modifier. Another advantage is a degree of flexibility contributed by the styrene comonomer.
The fibers of the present mat can be fibers of glass, wood pulp or particles, polyethylene, polypropylene, polyester, nylon, ORLON®* or mixtures of these fibers depending on the end use of the product. More specifically, for roofing shingles, acoustical boards, BUR and other asphaltic composites at least a major portion of glass fibers are employed and unmixed glass fibers are most desired. For facers or underlayment used in different articles of building construction, e.g. divider panels, other synthetic fibers or wood chips fixed in a mat can be utilized.
*a polyacrylonitrile (polyvinyl cyanide) continuous synthetic filament
The mat fibers generally have an average length of from about 3 to abut 140 mm and an average diameter of from about 5 to about 25 micrometers. Short and long fibers can be mixed to form a mat web of increased fiber entanglement.
The polysiloxane component of the mat is most preferably employed at a concentration of between about 0.05 and about 5% with respect to the modified binder and is a polysiloxane having repeating units of —Si—O—. The siloxane polymer can be modified with various substituents which include linear, branched or aromatic end-groups optionally containing oxygen, sulfur and/or nitrogen. Generally the present polysiloxanes are classified as polyalkyl-, polyaryl-, polyalkylaryl- and polyether-siloxanes. The polysiloxanes found to be most useful in the present invention are those having a weight average molecular weight of at least 600. The polysiloxanes listed in following Table 1 are representative.
TABLE 1
Polysiloxane
Mol. Wt.
Polyalkylene oxide-modified polydimethylsiloxane-
13,000
dimethylsiloxane copolymer
Polyalkylene oxide-modified polydimethylsiloxane-
3,000
dimethylsiloxane copolymer
Polyalkylene oxide-modified polydimethylsiloxane-
4,000
dimethylsiloxane copolymer
(Carboxylatepropyl)methylsiloxane-dimethylsiloxane
>1,000
copolymer
Dimethylsiloxane-(60% P0-40% EO) block copolymer
20,000
(Hydroxyalkyl functional) methylsiloxane-
5,000
dimethylsiloxane copolymer
Aminopropylmethylsiloxane-dimethylsiloxane copolymer
4,500
Aminoethylaminopropylmethoxysiloxane-dimethylsiloxane
>1,000
copolymer
Glycidoxy propyl dimethoxy silyl end blocked dimethyl
5,000
siloxane polymer
Methacryloxy propyl dimethoxy silyl dimethyl siloxane
40,000
polymer
Vinyl dimethoxy silyl end-blocked dimethyl siloxane polymer
6,500
Aminoethylaminopropyl dimethoxy silyl end blocked
3,800
dimethyl siloxane polymer
Amine-alkyl modified methylalkylaryl silicone polymer
7,800
Epoxy functional dimethylpolysiloxane copolymer
8,300
Dimethylpolysiloxane
26,439
Dodecylmethylsiloxane-hydroxypolyalkyleneoxypropyl
1,900
methylsiloxane copolymer
(Dodecylmethylsiloxane)-(2-phenylpropylmethylsiloxane)
>1,000
copolymer
Polyalkylene oxide-modified polydimethylsiloxane-
600
dimethylsiloxane copolymer
The modified binder of the present invention alters the interfacial effect between the mat and a surface coating which promotes fiber “pull out” during force applied to prevent immediate fiber breaking or tearing which occurs during separation of portions of the coated mat when the modifier is omitted. It is believed that the increased tear strength of the composite is due to an interfacial interaction between the coating and the mat containing the present modified binder which dissipates the force applied for separation.
IN THE DRAWING
The accompanying drawing is a top plan view illustrating the separation of a composite which comprises a glass fiber mat having an asphalt coating which penetrates the mat. The portions of the coated mat being separated are indicated by 2 and 4 with fibers 11 bridging the separated area and resisting disunion before total separation occurs.
For the manufacture of roofing shingles or BUR, a polysiloxane containing fiberglass mat with a urea/formaldehyde binder and the present crosslinked polymer modifier is preferred. The dried, cured mat may be covered on one or both sides with a conventionally thick coating of a standard asphalt or asphalt compound to produce a composite roofing product which can be cut to any size or shape or used as undivided BUR sheeting and packaged in pallets or rolls for shipment and subsequent installation. In the case of BUR roofing, however, coating or mopping of the mat with a hot surface coating of asphalt is generally delayed until a course of sheeting is installed on the roof. The asphalt employed for coating may additionally contain an antifungal, antibacterial, UV inhibitor and/or coloring agent at the option user.
The roof covering herein disclosed is a product of conventional weight and somewhat increased flexibility which meets and exceeds the requirements of ASTM D-3462 testing. The significantly improved tear strength of the present product results in savings in packaging and transportation of the product as well as durability of the product when installed.
Having thus generally described the invention, reference is now had to the following examples which illustrate particular and preferred embodiments but which are not to be construed as limiting to the scope of the invention as set forth in the appended claims.
EXAMPLES 1-8
Testing Tear Strength of 3×2.5 inch Samples of Shingles Employing Glass Fiber Mats With Urea/Formaldehyde (UF) Modified Binder.
Tear test D-1922, as referenced in ASTM D-3462 (Jul. 10, 1997 version), was used to determine the tear strength of various glass fiber mats coated on both sides with a 25 mil coating of asphalt conventionally used in roofing materials. In summary, the test measures the force in grams required to tear apart the coated mat specimen using a pendulum device. Acting by gravity, the pendulum swings through an arc tearing the specimen from a precut slit. The test specimen is held at one end by the pendulum and on the opposite end by a stationary member. The loss in energy by the pendulum is indicated by a scale and pointer which registers in the force required to tear apart the specimen.
To a wet web of 25-100 mm long glass fibers, derived from drainage of a white water slurry, was added at room temperature, a standard urea/formaldehyde binder containing 1 wt. % styrene/acrylate/acrylonitrile polymer modifier (i.e. Acronal S 886 S, supplied by BASF) to provide a fiber to modified binder weight ratio of about 80:20. The web containing fibers and modified binder is then sprayed with an aqueous solution of poly(dimethylsiloxane), supplied by Chem-Trends as product RCTW B9296) to provide a polysiloxane concentration of from 0.25 to 5% with respect to UF, as noted in the following table. The resulting webs were then dried and cured at about 300° C. for a period of 10 seconds to produce cured, non-woven mats, after which the mats were coated on both sides at 215° C. with filled asphalt (comprising 32% w/w asphalt and 68% w/w limestone filler) using a two-roller coater.
The styrene/butadiene latex, employed in the examples was supplied by Dow Chemical Co. and the urea/formaldehyde binder was obtained from Leste Co.
The results of these tests are as reported in following Table 2.
TABLE 2
Acronal
STYRENE/
TEAR
Ex.
UF
SILOXANE
5886 S
BUTADIENE
STRENGTH
No.
wt. %
wt. %
wt. %
wt. %
gram force (gf)
1
99
—
1
—
1241
2
98
1
1
—
2272
3
97
2
1
—
2415
4
96
3
1
—
3810
5
95
4
1
—
4418
6
97
5
1
—
4143
7
99
—
—
1
1217
8
98
1
—
1
1455
It will be understood that many modifications in procedure and substitutions in the compositions of examples 2-6, including substitution of the polysiloxane, binder and binder modifier, as well as fibers or fiber mixtures, can be made without departing from the scope of the present invention and that these examples merely represent preferred embodiments of the invention.
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The invention relates to a coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating which comprises a cured, non-woven, fiber glass mat containing a polysiloxane wherein the fibers are fixedly distributed in a formaldehyde type binder containing a binder modifier which is a crosslinked styrene/acrylic polymer, and to a process for the preparation of the mat.
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BENEFIT
The present application claims the benefit of U.S. Provisional Application No. 60/757,892, filed in the United States on Jan. 11, 2006, the entire contents of which are hereby incorporated herein by reference.
TECHNICAL FIELD
Embodiments of the present invention relate to a flooring and a floor panel with a continuous and unbroken front surface, which is at least partially light transmitting, providing for a light sign or pattern at the front face.
BACKGROUND
Embodiments of the invention may concern a laminate floor panel comprising a mechanical locking system, formed at least at two opposite edges and with a continuous and unbroken front surface, which is at least partially light transmitting. The following description of known techniques, problems of known systems and objects and features of embodiments of the invention will above all, as a non-restrictive example, be aimed as the field of the application. It should be emphasised that embodiments of the invention may be used in any floor panel and it could be combined with all types of known locking systems, for example, where the floor panels are intended to be joined using a mechanical locking system connecting the panels in the horizontal and vertical directions on at least two adjacent sides. Embodiments of the invention may also be applicable to, for example, solid wooden floors, parquet floors with a core of wood or wood-fibre-based material and a surface of wood or wood veneer and the like, floors with a printed and preferably also varnished surface, floors with a surface layer of plastic or cork, linoleum, rubber. Even floors with hard surfaces such as stone, tile and similar may be included and floorings with soft wear layer, for example, needle felt glued to a board. The invention can also be used for building panels, which preferably contain a board material, for example, wall panels, ceilings, furniture components and similar.
It is known that an illuminated floor can be assembled of wooden panels comprising illumination devices mounted through holes of the wooden panels, for example, as described in U.S. Pat. No. 5,095,412.
It is also known that an illuminated floor can be achieved by panels of glass or plastic assembled above illumination devices, for example, as described in DE 200 04 992 U1.
The illuminated floor panels known up to now have several disadvantages. There are apertures and notches at the front surface, due to the broken surface, which collect dust and moisture, and which apertures also lower the impact strength and the wear resistance. Alternatively, the panels comprise a surface of plastic or glass, which is a poor material for a floor panel with low strength and wear resistance. The known floor panels are also not aesthetically pleasing since they do not look like a normal panel and therefore do not blend in to a normal floor. Another disadvantage is that the known panels are difficult to assemble and disassemble, which is of great importance for a floor panel with a lighting means, since the lighting device must be possible to repair or exchange.
OBJECTS AND SUMMARY
Embodiments of the present invention may include a floor panel or flooring with a light means, in particular a laminate floor panel, which provides for new embodiments according to different aspects offering respective advantages. A useful area for the floor panels are public flooring, e.g. in stores, restaurants, ships, hotels and airports, for information signs or decoration.
According to a first aspect, embodiments of the invention provides for a laminate floor panel, which is at least partly light transmitting, comprising a front face, a rear face, a surface layer of resin-impregnated sheets and a wood-based core. The light transmitting is preferably obtained by removing parts of the core or even parts of the surface layer to such an extent that a light source located under the floor surface is visible at the front face.
According to a preferred embodiment of this first aspect there is an aperture at the rear face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The aperture is preferably formed by mechanical working, e.g. drilling and chipping.
Laminate flooring usually comprises a core of a 6-9 mm fibreboard, a 0.2-0.8 mm thick upper decorative surface layer of laminate, preferably comprising sheet material impregnated with thermosetting resins and a 0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper or like mate-vial. The surface layer provides appearance and durability to the floorboards; and preferably contains at least one layer imprinted with a pattern, for example a wood pattern printed on a paper layer. The core provides stability, and the balancing layer keeps the board plane when the relative humidity (RH) varies during the year. The floorboards are generally laid floating, i.e. without gluing, on an existing subfloor.
The front surface of the floor panel according to the first aspect of the invention may be a wear resistant material, covering any object under the panel, and is continuous and also a natural floor material. A first advantage is that there are no dust or moisture collecting apertures or notches at the front surface. A second advantage is that when the lighting means is turned of, the floor panel looks just like a normal floor. A third advantage is that the floor panel has a high wear and impact resistance.
Preferably, a mechanical locking system is formed at least at two opposite edges of the floor panel, which facilitates the joining of a similar floor panel or a normal floor panel, which is not partly light-transmitting. Mechanical locking system joined by angling are for instance known from WO 94/26999, which is especially advantageous at the long sides of a rectangular floor, and another locking system especially advantageous at the short sides, particularly when combined with an angling locking system like the one described in WO 94/26999, are described in PCT/SE2005/001586, owner Valinge Innovation AB. Other shapes of floor panels are also possible. One advantage in providing an illuminated floor panel with a mechanical locking system is that when you want or need to change an illuminated floor panel, due to failure of lighting means or a desire to have another light sign/symbol, it is simple to disassemble such floor panels and to change the illuminated panels. The above mentioned combination of locking systems make it possible to join floor panels by several methods, preferably with a single action method, where the long edge is installed with angling and the short edge, which is provided with a flexible tongue, with vertical folding. This combination is also very easy to disassemble. Other mechanical locking system are also known, and possible to use, which are joined by Angling-Angling, Angling-Snapping or Snapping-Snapping. Floor-boards with a mechanical locking system are generally laid floating, i.e. without gluing, on an existing subfloor.
Evidently it is also possible to use a tongue and a groove joint, usually combined with gluing or nailing or other fastening means.
According to an embodiment of the first aspect, the wood based core is made of MDF or HDF.
According to another embodiment, lighting means is mounted into the aperture. It is also possible to connect a conductor to the lighting means and in the same or another aperture a battery cell and/or a receiver and/or a control unit. The aperture is preferably filled with a filling material, preferably light transmitting.
The thickness of the transmitting layer is adapted to the power of the lighting means, with the aim of facilitating light to transmit through the transmitting layer. The transmitting layer preferably comprising substantially the surface layer or the surface layer and a part of the core under the surface layer.
According to a second aspect, embodiments of the invention provide for a floor panel comprising a light-transmitting core of plastic or glass and a surface layer of resin-impregnated sheets, which is also at least partly light transmitting. It is feasible to mount a light means under the floor panel, preferably in a subfloor or into an aperture. An advantage with this system is that it is easier to mount, connect and control the lighting means; the draw back is that the subfloor normally has to be worked or changed. It is also possible to combine a floor according to the first aspect with such a sub-floor comprising a lighting means, provided that if there is a filler, the filler is light transmitting.
According to a first embodiment of the second aspect, only a part is light transmitting. Before attaching the surface layer to the light-transmitting core the rear side of the surface layer is worked, chemically or mechanically, forming a thinner part with a light-transmitting layer. Preferably, the space between the transmitting layer and the core is filled with a light transmitting filler, e.g. resin. An advantage of this embodiment is that it is possible to create a light pattern with only one lighting means.
According to second embodiment of the second aspect, the whole surface layer is light transmitting and the light pattern at the front surface is formed by the lighting means solely. Another possibility is that there is a second layer between the surface layer and the core, which is partly light transmitting, or the attaching means has various light transmitting properties, forming the light pattern at the front surface.
In both embodiments the attaching means also is preferably light transmitting, at least at the transmitting layer. The thickness of the transmitting layer, respectively in the first embodiment and of the surface layer in the second embodiment, is adapted to the power of the lighting means, with the aim of facilitating light to transmit.
Preferably, a mechanical locking system is formed at the edges, alike as in the first aspect, resulting in the same advantages.
In the first and second aspect of the invention the resin impregnated sheets could be replaced with a wood veneer, preferably treated with oil or varnish.
According to a third aspect, embodiments of the invention provide for a floor panel comprising a solid wood body, an aperture at the rear face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The aperture is preferably formed by mechanical working, e.g. drilling and chipping and the front surface preferably treated with oil or varnish.
Preferably, a mechanical locking system is formed at the edges, alike as described in the first aspect, resulting in the same advantages.
According to another embodiment of the third aspect a lighting means is mounted into the aperture. It is also possible connect a conductor to the lighting means and in the same or another aperture a battery cell and/or a receiver and/or a control unit. The aperture is preferably filled with a filling material, preferably light transmitting. Another solution is to mount a light means under the floor panel, as described in the second aspect, resulting in the same advantages.
The thickness of the transmitting layer is adapted to the power of the lighting means, with the aim of facilitating light to transmit through the transmitting layer.
According to a second object, embodiments of the invention provide for a flooring comprising at least one of the floor panels above in the first object, joined to one or more similar floor panels or one or more normal floor panels, which are not partly light-transmitting.
Preferably the flooring is joined on a sub-floor comprising a lighting means mounted in e.g. an aperture or recess of the sub-floor.
A preferred lighting means is a light emitting diode, due to the low heat generation and small size.
In view of the above, an objective of embodiments of the invention is to solve or at least reduce the problems discussed above.
In particular, an objective of embodiments of this invention is to provide a floor panel with a light pattern/sign, which when an accompanying light means is turned off looks like a normal floor panel, and due to the front face of the floor panel being of a normal floor material the wear resistance is high. There are also no dust and moisture collecting apertures and recesses at the front face.
An advantage of forming a mechanical locking system at the edges of the floor panel is that it is easy to assemble and also disassemble and change the floor panel with the light pattern/sign.
All references to “a/an/the [element, device, component, means, step, etc]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 a - b are a schematic top plan view and a schematic bottom view respectively of a floor panel according to one embodiment of the invention,
FIG. 2 shows a view whereby panels are joined by a single-action, angling at one edge and vertical folding at an adjacent edge.
FIGS. 3 a - d show in cross-section different embodiments of the invention.
FIGS. 4 a - c show in cross-section different embodiments of a floor panel mounted on a sub-floor with a lighting means.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As represented in FIGS. 1 and 2 , embodiments of the invention relate to a floor panel and a flooring, provided with a light sign or pattern. The sign or pattern is preferably not visible when a related lighting means is turned off, and in that state the floor panel or the flooring looks just like a normal floor and all the features related to the lighting are covered. The lighting means is mounted in the floor panel or in a sub-floor.
According to a first aspect of the invention, a laminate floor panel 1 , at least partly light transmitting, may comprise a front face 2 and a rear face 3 and a light sign or a decoration 9 is provided at the front face. The floor panel may further comprise, as shown in FIGS. 3 a - c , surface layer 33 of resin impregnated sheets or a wood veneer, a wood based core 35 , an aperture 31 at the rear-face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The thickness of the transmitting layer is adapted to the power of an accompanying lighting means 36 , aiming at facilitating light to transmit through the transmitting layer. The sign or decoration 9 is preferably only visible when the related lighting means is turned on and the lighting means it self and the aperture is preferably never visible from the front face. In one alternative, the transmitting layer 32 only comprises the surface layer 33 and in a second alternative the transmitting layer 32 ′ also comprises the core 35 . The aperture 32 is at least partly preferably filled with a filler 37 , preferably light transmitting.
Preferably a mechanical locking system 6 , 6 ′ is formed at least at two opposite edges 5 a , 5 b or 4 a , 4 b . The most preferred mechanical locking system comprising a flexible tongue, which results in a very simple assemble and disassemble operation, facilitating the change of the floor panel with the light sign. The floor panel 1 in FIG. 2 is joined along a first edge 5 b to a second edge of an adjacent floor panel 1 ′, with a mechanical locking system 6 ′ comprising a flexible tongue 10 , by vertical folding, and along a third edge 4 b to the fourth edge 4 a of another adjacent floor panel 1 ″, with a mechanical locking system 6 , by angling. The whole panel 1 is joined in a single action. Other known mechanical locking systems for floor panels are also possible to use.
One alternative is to attach the lighting means into the aperture and connect it with a conductor 39 and via the conductor control the lighting means by a control unit C. A battery cell B and a receiver R is also possible to connect via the conductor. A second alternative is to mount the lighting means and a battery cell in the same aperture, together with preferably a receiver R and a control unit C. The conductor is preferably attached into a recess of the floor panel and covered with a filler, e.g. resin. One example of a lighting means is a light emitting diode and another example is fibre optic. If fibre optic is used, the conductor is a fibre optic cable.
The wood-based core is preferably a particle, MDF or HDF board.
According to a second aspect of the invention, represented in FIGS. 4 b - c , the floor panel comprising a core made of a light transmitting material 40 , such as plastic or glass and a surface layer 33 of resin impregnated sheets or wood veneer, which are at least partly light transmitting. The floor panels are mounted on a sub-floor 41 , comprising a lighting means 36 , preferably a light emitting diode, mounted into an aperture 43 of the sub-floor. One alternative is to connect the lighting means with a conductor 39 mounted into a recess 42 of the subfloor and via the conductor control the lighting means by a control unit C. A battery cell B and a receiver R is also possible to connect via the conductor. A second alternative is to mount the lighting means and a battery cell in the same aperture, together with preferably a receiver R and a control unit C. Also the floor panel according to the second aspect is preferably joined by a mechanical locking system, alike as described above.
In one embodiment, see FIG. 4 b , the surface layer has at least one area comprising a thinner and light transmitting layer, which is mechanically or chemically worked. A space 44 between the core 40 and the transmitting layer is preferably filled with a light transmitting filler.
In a second embodiment, see FIG. 4 c , the whole surface layer 33 is light transmitting. The pattern or sign at the front face is in this embodiment formed by the formation of the lighting means 36 . Is it also possible to form the light pattern or the sign at the front face by an additional layer between the surface layer and the core or by the attaching means used for attaching the surface layer to the core. The additional layer could be punched or could have a printed pattern, which is at least partly visible from the front face. In this case, the additional layer and the attaching means has light-transmitting properties, which varies over the front surface. The design of the whole floor panel could be changed if the surface is light transmitting. The appearance of several panels in a floor could for example be varied over time by changing the light intensity in individual floor panes. This will create a new design element which could be very attractive in for example show rooms, shops etc.
A third aspect of the invention, represented in FIG. 3 d , is a partly light-transmitting floor panel, comprising a body 38 of solid wood, an aperture, a lighting means 36 , and a transmitting layer 32 ″ between the bottom of the aperture and the front face. The aperture is preferably, at least partly, filled with a filler. The features described above for the first aspect and related to the mechanical locking, the lighting means, the battery cell, the receiver and the control unit are applicable also to a floor panel according to the third aspect. FIG. 4 a shows that it is also possible to mount a floor panel according to the first and third aspect on a sub-floor comprising a lighting means.
The thickness of the transmitting layer, described above in the different aspects of the invention, is preferably in the range of 0.05-1 mm and most preferably in the range of 0.3-0.7 mm. The thickness depends of the power of the lighting means and the light transmitting properties of the material, and to some extent also the strength of the material. Most materials suitable for flooring could be light transmitting if they are made thin enough. Stone, tiles and a lot of different plastic and wood based materials are possible to use. In metal surfaces for example micro openings which are not visible from the surface could be made and preferably filled with a light transmitting material
A second object of embodiments of the invention is a flooring comprising at least one of the floor panels above, joined to one or more similar floor panels or one or more normal floor panels, which are not partly light-transmitting.
Embodiments of the invention have mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended claims.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein.
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The present invention relates to a floor panel and a flooring with a preferably continuous and unbroken front face, which is at least partially light transmitting and which has a light pattern/sign at the front face.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of copending application Ser. No. 907,294 filed Mar. 6, 1978, now abandoned.
BACKGROUND OF THE INVENTION
The present invention concerns the problem of correctly tensioning the thread used in a sewing machine.
Very often in sewing machines, when the user swings up the presser-foot lever of the machine, to raise the cloth presser foot from cloth-engaging to inoperative position, the machine's thread-tension disks are relieved, to terminate tensioning action. This is done so that thread can be freely drawn from the thread spool in the course of manually repositioning the workpiece for continued sewing, or as an incident to removal of the workpiece from the machine. In some machines, there is a complete loss of thread tension when the cloth presser foot is raised to inoperative position. However, this can be very disadvantageous for the case where basting work is done with the pressure foot kept raised, because a situation of insufficient thread tension can readily occur. In some machines, of the type where the thread-tensioning action is terminated upon raising of the presser foot, the mechanism employed is such that the thread-tensioning action happens to be progressively decreased in the course of raising the presser foot to inoperative position. A disadvantage with mechanisms of that type is that, when sewing a very thick workpiece, e.g., consisting of several layers of thick cloth, the presser foot may be kept elevated from its lowermost position by the thick workpiece itself, resulting in an incidental and inappropriate thread-tension decrease. Some sewing machines maintain non-zero upper thread tension, even when the cloth presser foot is raised to inoperative position, and this is potentially useful for basting work performed with the presser foot elevated. However, beyond the mere fact of non-zero upper thread tension in such a situation, it would really be necessary to be able to finely adjust the thread tension value, dependent upon the particular basting job involved, but this has been very difficult to provide and in general when the cloth presser foot is in raised, inoperative position, no fine-adjustment capability remains for thread-tension control.
Problems of appropriate thread-tension action can be particularly troublesome in the case of sewing machines having stitch-pattern capabilities, e.g., machines able to implement stitch-patterns of intricate configuration by resort to the now familiar pattern-ROM technique. In such patterns, the needle bar of the machine may be transversely displaced proceeding from one constituent needle-penetration location of a stitch-pattern to the next by transverse distances varying greatly from one constituent stitch of the pattern to the next, and likewise the amount and the direction of the cloth feed increment may vary from one needle-penetration action to the next with a considerable frequency and range of variation within the course of a single stitch-pattern. Furthermore, some stitch-patterns may be constituted by intervals of intricate stitch configuration alternating with intervals of simple straight stitching, further adding to the complexity of the tension-control aspect of pattern implementation. In general, the user of the machine is able to manually adjust thread tension, e.g., prior to commencement of automatic sewing of a particular stitch-pattern, but it is not in general feasible to manually adjust thread tension during the course of implementation of the successive stitches of such a stitch-pattern.
In addition to the tension-control implications of an intricate stitch-pattern geometry, the user must, of course, furthermore take into account factors of workpiece thickness and the thickness and character of the thread employed, e.g., slick thread or rough thread in the case of disk-type tensioning mechanisms which establish thread tension by mere frictional drag on the thread. These various factors can make it far from self-evident to the operator how the thread tension should be set for a particular job.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide sewing-machine tension-control systems which overcome the disadvantages and limitations of the prior art.
In accordance with various features of the present invention, use is made of an electromechanical thread-tension varying mechanism which varies thread tension in dependence upon an electrical thread-tension command signal, with the value of the thread-tension command signal being automatically selected and/or automatically varied in a variety of situations without the need for the user to consciously participate in this automatic action. Advantageously, however, the user is provided with means for manually modifying the thread-tension command signal, in situations where the user deems it appropriate to deviate from the automatically selected tension values.
In one embodiment of the invention, when the user manually selects a stitch-pattern from a plurality of available stitch-patterns, the tension-control system automatically responds by selecting a thread-tension value appropriate for the selected stitch-pattern. An auxiliary, manually operated selector, which may for example normally be kept in a particular setting, is provided for use in those instances where the user feels it necessary to deviate from the automatically selected and pattern-dependent tension value. When the user raises the machine's cloth presser foot, e.g., in order to do basting work with the presser foot kept in raised position, the tension-control system responds by automatically selecting a low but non-zero tension value, which the user can finely adjust, if necessary, preferably by means of the same auxiliary selector just mentioned.
In another embodiment of the invention, a pattern memory stores, in its addressable storage locations, not only stitch-control data used to command the successive stitches of a stitch-pattern, but in addition thereto actual tension-control data for each successive stitch of such stitch-pattern, and the tension command signal is derived from the tension-control data, so that the thread tension for each stitch of the pattern be appropriately and automatically selected, with the user, however, retaining the ability to apply a manually selected corrective factor to this sequence of automatically generated thread-tension command signals, e.g., for extremes of cloth thickness, and the like.
In a further embodiment, the pattern memory is not called on to store tension-control data per se, and thereby need not have an increased bit capacity for such additional data. Instead, computational circuitry derives from the mere stitch-control data presented by the memory distance-dependent values dependent upon the physical distances between one constituent needle-penetration location of a stitch-pattern and the next, again with the user having the ability to apply a corrective factor for extremes of cloth thickness, and the like.
In another embodiment, in order that the user be as seldom as possible called on to apply such corrective factors, the tension command signal is derived from a nominally-required-tension signal, which does not take into account factors such as workpiece thickness and thread thickness and character, but which is then automatically compensated in dependence upon signals which indicate workpiece thickness and thread thickness and character. The user is still provided with the ability to apply a corrective factor to the automatically generated tension command signals, but need do so only when the automatic compensation for workpiece thickness and thread character fails, for whatever reason, to produce a convincing and satisfactory end product.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 depicts a first electromechanical tension-varying device;
FIG. 2 depicts the device of FIG. 1 in end view, and also certain other components of a sewing machine;
FIG. 3 depicts an exemplary embodiment of a control circuit for the tension-varying device of FIG. 1;
FIG. 4 depicts an exemplary stitch-pattern, referred to in explanation of certain problems of thread-tension control;
FIG. 5 depicts a second exemplary embodiment of a control circuit for the device of FIG. 1;
FIG. 6 depicts a third exemplary control circuit for the device of FIG. 1;
FIG. 7 depicts a second electromechanical tension-varying device;
FIG. 8 is a schematic block diagram of a control circuit for the tension-varying device of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 depict an exemplary version of the electromechanical part of a thread-tension control system embodying the present invention.
In FIG. 1, numeral 1 denotes a plunger-type solenoid whose stator 2 is bracket-mounted on a wall 3 of the housing of a sewing machine. Numerals 4 and 5 denote two cooperating thread-tension disks between which the sewing thread is guided and pressed for thread-tension control. The two thread-tension disks 4, 5 have central apertures through which freely passes the armature 6 of the plunger-type solenoid 1. Armature 6 has a smaller-diameter right part 6' and a larger-diameter left part 6". The two tension-control disks are axially confined intermediate two bearing plates 7, 8 likewise encircling the smaller-diameter part 6' of armature 6. A stop member 9 is screwed to the end of part 6' of armature 6, so that when armature 6 is pulled leftward stop member 9 press the disks 4, 5 and the bearing plates 7, 8 together. When the coil 10 of solenoid 1 is energized more strongly, armature 6 is more strongly pulled leftward; when the energization of coil 10 is lowered, armature 6 is less strongly pulled leftward, resulting in a corresponding relaxation of the force with which the tension-control disks 4, 5 are pressed against each other, and thereby resulting in a correspondingly lowered thread tension. The degree of thread tension resulting from a certain value of energizing current for solenoid winding 10 can be adjusted by releasing the adjusting screw of stop member 9 and resetting the position of member 9 on armature 6. G denotes the gap between leftmost position of armature 6 and the position which it is constrained to occupy in an exemplary instance of tension-control action.
FIG. 2 depicts further mechanical components involved in thread-tension control, shown mounted on a sewing-machine housing depicted in end view. Numeral 11 denotes the user-operated presser-foot lever of a sewing machine. Presser-foot 11 pivots about a pivot screw 12, and is swung by the user to its upper illustrated setting when the machine's (non-illustrated) cloth presser foot is to be raised out of pressing engagement with the cloth being sewn; lever 11 is swung down by the user when the cloth presser foot is to be lowered into pressing engagement against the sewn cloth. Numeral 13 denotes a single-pole, double-throw microswitch having an actuator button 15. The end 14 of presser-foot lever 11 acts as a cam, depressing actuator button 15, and thereby causing microswitch 13 to assume one of its two states, when lever 11 is in its illustrated raised position, end 14 of lever 11 permitting button 15 to release when the presser-foot lever 11 is swung down to operative position, thereby causing microswitch 13 to assume the other of its two states. Numeral 11' denotes the presser-foot rod controlled by lever 11, and at the bottom end of which the conventional (non-illustrated) cloth presser foot is articulately mounted in the usual way. Also shown in FIG. 2 is the location on the machine housing of the tension-control mechanism of FIG. 1.
FIG. 3 depicts an exemplary embodiment of a control circuit which can be used to control the energization of the winding 10 of the solenoid 1 of FIG. 1. As shown in FIG. 3, the microswitch 13 includes a movable contact C, whose setting is determined by the setting of actuator button 15 of FIG. 2, and two stationary contacts N O and N C alternatively engaged by contact C.
When presser-foot lever 11 is raised to inoperative position, e.g., for basting work, contact C engages contact N O , connecting a resistor 16 in series with a potentiometer 18, an adjustable resistor 19 and a fixed resistor 20, forming a voltage divider connected between operating voltage +V and ground.
When presser-foot lever 11 is swung down to operative position, for normal sewing, contact C engages contact N O , thereby disconnecting resistor 15 from resistor elements 18-20, and instead connecting to the latter the parallel connection of a resistor 17 and one of a set of resistors R 1 , . . . , R n . Each of resistors R 1 , . . . , R n is connected in series with a respective normally open pattern-selector switch S 1 , . . . , S n . The sewing machine is of the type provided with a (non-illustrated) patterning mechanism affording the user a plurality of selectable stitch-patterns, selectable, e.g., by means of a row of pushbuttons provided on the exterior of the machine housing, the patterning mechanism being either of the electrical, the electronic or the cam-controlled type, each of these types of patterning systems being conventional and familiar to persons skilled in the art. When, for example, the n-th of the available stitch-patterns is selected by the user, this locks switch S n in the illustrated closed setting thereof, thereby connecting resistor R n in parallel with resistor 17.
The wiper of potentiometer 18 is connected to the non-inverting input of an operational amplifier 21 whose output is connected to the base of a transistor 22. The collector-emitter path of transistor 22 is connected, in series with solenoid winding 10 and a fixed resistor 23, between operating voltage +V and ground. The junction between solenoid winding 10 and resistor 23 is connected to the inverting input of operational amplifier 21, for negative-feedback purposes, to form a constant-current source whose output current is determined by the voltage applied by the wiper of potentiometer 18 to the non-inverting input of amplifier 21.
Resistor 19 is a factory- or service-adjusted resistor, for adjustment of the range of values of current driven through solenoid winding 10. Potentiometer 18 is adjusted by the user of the sewing machine, e.g., for the purpose of adjusting an automatically selected value of thread tension when particularly thin and fragile or particularly heavy and tough cloth is involved; the wiper of potentiometer 18 may, for example, have a middle setting in which it is normally maintained by the user, except when the user thinks it appropriate to depart from an automatically selected thread-tension value.
When presser-foot lever 11 is elevated, e.g., for basting, and accordingly contact C engages contact No, the energizing current for solenoid 10, and accordingly the thread-tension value, is established in dependence upon the resistance of resistor 16. If the presser-foot lever 11 is swung down to operative position, contact C engages contact N C , and the energizing current of solenoid 10 assumes a value depending upon which one of pattern-selector switches S1, . . . , S n is closed. The resistance values of resistors R 1 , . . . , R n differ from one another, and each is so dimensioned as to result in a thread-tension value appropirate for the stitch-pattern selected by the respective selector switch S 1 , . . . , S n . The resistance value of resistor 16 is higher than that of the parallel combination of resistor 17 and any single one of the pattern-dependent resistors R 1 , . . . , R n , as a result of which the thread-tension value associated with the raised, inoperative position of presser-foot lever 11 will be the lowest one of the automatically selected thread-tension values. When the presser foot of the machine is raised at the end of an interval of sewing, it is thereby achieved that a predetermined non-zero value of thread-tension is automatically maintained, to prevent tangling of the thread, and the like. Likewise, if presser-foot lever 11 is kept in raised, inoperative position during basting work, a non-zero value of thread tension is automatically maintained. Furthermore, the automatically selected thread-tension value is adjustable by means of user-operated potentiometer 18, so that exactly the right tension value for a particular instance of basting work can be easily set.
FIG. 5 depicts another control circuit for controlling the energization of solenoid winding 10 of FIG. 1. Numeral 39 denotes a conventional pattern ROM storing the stitch-control data for successive stitches of one or more stitch-patterns in individually addressable internal storage locations. Each storage location has a 12-bit capacity, and when any one such storage location is addressed, the first five bits stored therein appear at the five outputs 40 of ROM 30, the second five bits stored therein at outputs 41, and the last two bits at ROM outputs 44 and 45. In conventional manner, the five bits at outputs 40 are used as a needle-bar position command, and successive 5-bit commands are applied to the machine's needle-bar positioner unit 42; the five bits at outputs 41 constitute a cloth-feed command, and successive cloth-feed command are applied to the machine's cloth feeder unit 43. The two additional bits contained in each addressable storage location, and appearing at outputs 44, 45 when a storage location is addressed, serve as tension-control data. The binary signals produced at ROM outputs 44, 45 are applied to the left terminals of respective resistors 46 and 47 (if necessary, via appropriate interface stages, such as amplifiers). The right terminals of resistors 46 and 47 are connected in common with the right terminal of a resistor 48, to whose left terminal is applied a voltage V D . The resistance values of resistors 46, 47, 48 and the voltage V d are so dimensioned that the four possible combinations of two bits produced at ROM outputs 44, 45 result in the establishment of four differing voltages at the right terminals of resistors 46, 47, 48.
Numeral 13' denotes a microswitch, activated in the manner of microswitch 13 of FIG. 2. When the presser-foot lever is raised to inoperative position microswitch 13' is open as shown; when the presser-foot lever is lowered to operative position microswitch 13' closes and applies the voltage at the right terminals of resistors 46, 47, 48 to the upper terminal of a user-operated potentiometer 49. The wiper of potentiometer 49 is connected to the non-inverting input of an operational amplifier 50, whose input is connected to the base of a transistor 15, the collector-emitter path of which is connected in series with solenoid winding 10 and a fixed resistor 52 between operating voltage +V and ground. The junction between solenoid winding 10 and resistor 52 is connected to the inverting input of operational amplifier 50, so that amplifier 50 together with transistor 51 act as a constant-current source having a solenoid winding 10 as its load. Potentiometer 49 may, for example, have a specially marked normal setting, in which it is left by the user when no departure from automatically selected thread-tension values is required, with the user moving the wiper of potentiometer 49 out of normal setting when, for example, extremes of cloth thickness or thinness or grades of thread are involved.
During the implementation of a stitch-pattern, successive storage locations of pattern ROM 39 are read out, the twelve bits of control data in each such storage location appearing at outputs 40, 41 and 44, 45 of the ROM. For each successive stitch of the stitch-pattern, a respective 2-bit thread-tension control signal is produced at outputs 44, 45, resulting in the establishment of a respective one of four differing levels of energization of solenoid winding 10. Accordingly, the thread tension can, if necessary, be changed from one stitch of the stitch-pattern to the next.
The ability to automatically vary the thread-tension value from one stitch of a stitch-pattern to the next can be of considerable benefit for certain types of stitch-patterns. For example, in the arrowhead pattern depicted in FIG. 4, where the successive needle penetrations of the pattern are denoted by consecutive numbers, it will be evident that a relatively lower thread-tension value is appropriate for the initial stitches of the pattern, and a relatively higher tension value for the last stitches of the pattern.
In FIG. 7, for the sake of simplicity, a 2-bit tension-control signal is produced by ROM 39. However, it will be understood that, if more than four automatically selected tension values are to be afforded, it would merely be necessary to use a greater number of bits for the tension-control code word employed. Likewise, the particular interconnection of resistors 46, 47, 48 is merely explanatory, and other configurations will be evident. For example, in FIG. 3 each of the switches S 1 , . . . , S n could be an electronic switch whose control electrode is controlled by a respective one of the bits of the tension-control code word produced by the pattern ROM.
In FIG. 5, by way of example, when the presser-foot lever is swung up to inoperative position, microswitch 13' simply opens, with the result that the thread tension drops to zero, for example to whatever low value might be afforded by a biasing spring bearing against the tension-control disks employed. Alternatively, however, the microswitch 13' of FIG. 5 could be provided as a double-throw switch like 13 in FIG. 3 cooperating with a fixed resistor like resistor 16 of FIG. 3, so that the tension value established when the presser foot is in raised, inoperative position be, here likewise, electrically established and then also adjustable by means of the user-operated potentiometer.
In the control circuits of FIGS. 3 and 5, and the other exemplary ones disclosed herein, it can also be advantageous to automatically interrelate the thread-tension value with a manually selected cloth-feed increment for ordinary straight stitching. For example, when one of the selectable stitch-patterns is not to be used, but instead the machine is to form mere straight stitching, the input of amplifier 21 of FIG. 3 or 50 of FIG. 5 could be disconnected, by suitable switching action, from the illustrated circuitry and instead connected to the wiper of another potentiometer, the wiper being mechanically coupled to the clotch-feed-increment selector dial of the machine. In that way, when the user manually selects a longer cloth-feed increment for simple straight stitching, this would automatically serve to reduce the thread-tension value established; and when the user manually selects a shorter cloth-feed increment for straight stitching, this would serve to automatically raise the thread-tension value employed.
In the control circuit of FIG. 5, the thread-tension value is automatically varied, if necessary, from one constituent stitch of a stitch-pattern to the next, but this requiring that each addressable storage location of the pattern ROM 39 have extra bit-capacity for the tension-control code word which governs this action. FIG. 6 depicts a similar embodiment in which, however, no such additional bit-storage capacity is required for the pattern ROM.
The pattern ROM 39a of FIG. 6 transmits needle-bar position commands from its output 40 to the machine's needle-bar positioner unit 42, and feed commands from its outputs 41 to the machine's cloth feeder unit 43, as in the embodiment of FIG. 5. Pattern ROM 39a does not per se produce separate tension-control output bits. Instead, appropriate tension-control signals for each successive stitch of a stitch-pattern are derived from the mere stitch-control data produced by ROM 39a. In particular, the thread tension value to be established between each constituent needle penetration of a stitch-pattern and the next needle penetration is automatically ascertained by subtracting each needle-bar position command from the preceding needle-bar position command, the position commands being expressed as 5-bit binary code words whose numerical values correspond to different respective transversely displaced positions of the machine's needle bar, i.e., such that the binary-arithmetic difference of two successive 5-bit needle-bar position commands directly correspond to the physical distance between the two commanded needle-bar positions.
Each 5-bit needle-bar position command produced at outputs 40 of pattern memory 39a is applied to the input of a digital-to-analog converter D/A. The analog version of the needle-bar position command produced at the output of converter D/A is applied either to a holding capacitor C 1 or to a holding capacitor C 2 , depending upon which of two respective analog switches AS 1 , AS 2 is briefly closed. Pattern ROM 39a has two gating-signal outputs G 1 and G 2 . When the address signal applied to the (non-illustrated) address-signal input of ROM 39a changes, ROM 39a produces an output pulse at gating-signal output G 1 just before the data for the newly addressed ROM storage location actually appear at ROM outputs 40, 41. The pulse produced at output G 1 renders analog switch AS 1 briefly transmissive, and the analog position-indicating signal present at the output of converter D/A is registered by holding capacitor C1. Just after the data in the newly addressed storage location appear at the outputs 40, 41 of ROM 39a, a brief pulse is produced at gating-signal output G 2 , rendering analog switch AS 2 briefly conductive so that the analog version of the new needle-bar position command be registered by holding capacitor C 2 .
The voltage held on capacitor C 1 is transmitted via an operational amplifier OP 1 to the input resistor R A of an operational amplifier OP 3 provided with a feedback resistor R E . The voltage held on capacitor C 2 is transmitted via an operational amplifier OP 2 , but additionally via an operational-amplifier inverter R B , OP 4 , R C , to the input resistor R D of operational amplfier OP 3 . Accordingly, the input signal received by the inverting input of operational amplifier OP 3 directly corresponds to the difference between the new needle-bar position command and the preceding needle-bar position command.
The output signal of OP 3 is applied to an absolute-value generator comprised of operational amplifiers OP 5 , OP 6 , diodes D 1 , D 2 , and resistors R F , R G , R H , R I , R J . The absolute-value generator produces a signal whose magnitude depends upon the difference-signal produced by OP 3 but whose polarity is independent of the polarity of the difference-signal. The absolute-value version of the difference-signal is applied via a resistor R K , a switch 36a and a potentiometer 49a to the non-inverting input of an operational amplifier OP 7 . The junction between resistor R k and switch 36a is connected to a source of negative operating voltage -V REF via a resistor R L . Operational amplifier OP 7 is connected with a transistor Tr and a resistor R M to form a constant-current source whose load is constituted by solenoid winding 10.
As each stitch of the pattern read out from ROM 39a is commanded, the energizing current flowing through solenoid winding 10 is automatically adjusted to a value corresponding to the distance between the two sucessive needle penetration locations involved.
FIG. 7 depicts an alternative electromechanical mechanism for thread-tension control. A reversible electric motor 53 drives a shaft 54 having a threaded section 54a. An internally threaded stop member 55 is threaded on threaded portion 54a and shifts in the direction axially of shaft 54 as the latter is rotated by motor 53 in one or the opposite direction. A helical compression spring 56 is confined axially intermediate stop member 55 and one of two tension-control disks 57. The biasing pressure of compression spring 56 is adjusted by adjusting the axial position of stop member 55 along the length of the threaded portion 54a of shaft 54. Compression spring 56 presses the tension-control disks 57 leftwards against a pressure-bearing member 58 provided with a pressure transducer 59, e.g., a strain gauge, operative for producing an electrical signal indicative of the force with which the tension-control disks 57 are being pressed together. Additionally, reversible electric motor 53 may be provided with a rotary transducer 100 operative for generating a signal indicating the angular position of output shaft 54 over a range of angular values equal to a multiple of 360° , i.e., for a range of angular positions spanning several rotations of output shaft 54.
FIG. 8 depicts an exemplary control circuit for controlling the reversible electric motor 53 of FIG. 6. In FIG. 8, motor 53 is energized by an actuation stage 66, which may for example be essentially comprised of a power amplifier. Actuation stage 66 receives at its input a signal depending on the difference, i.e., the error, as between the actual pressure with which the tension-control disks 57 are being pressed together, on the one hand, and, on the other hand, the pressure with which disks 57 are commanded to press against each other. This error signal is furnished by a comparator of subtractor 61. The right input of subtractor 61 receives a signal indicative of the pressure with which disks 57 are actually being pressed together. This signal is furnished by pressure transducer 59, through the intermediary of an amplifier 60 which will in general amplify the pressure-transducer output signal and, possibly also, have a non-linear transfer function compensatory for any non-linear pressure-versus-output-signal behavior on the part of pressure transducer 59. The left input of subtractor 61 receives a signal commanding the requisite value of pressure for disks 57. This command signal is in analog form and is produced at the output of a digital-to-analog converter 65, whose input receives a digital version of the same signal. Numeral 67 denotes a manually operated adjuster stage which can be operated when the user wishes to depart from the automatically selected thread-tension values. Manual adjuster stage 67 may, for example, essentially consist of an adjustable voltage divider serving to multiply by a manually adjusted factor the analog voltage produced by stage 65.
The digital version of the pressure command signal received by digital-to-analog converter 65 is furnished by a calculator and/or memory circuit 64. Calculator circuit 64 receives, from a stage 62, a signal indicative of a nominally required thread-tension value. The nominal-tension signal may be a respective constant signal for each of a plurality of selectable stitch-patterns, e.g., as in FIG. 3 where selection of one pattern produces a nominal tension command for the selected pattern (the merely nominal tension command being adjustable by means of user-operated potentiometer 18, in order to take into account factors such as cloth thickness, thread thickness and type). Alternatively, the nominal tension command signal produced by stage 62 of FIG. 9 may be derived from thread-tension control bits such as produced at outputs 44, 45 of pattern ROM 39 of FIG. 5. Or stage 62 may produce the nominal tension command signal in the manner of FIG. 6, i.e., by computing the physical distance between successive neelde-penetration locations of a stitch-pattern on the basis of the stitch-control data which implement the stitch-pattern.
Calculator circuit 64 furthermore receives, from a stage 63, data identifying those characteristics of the thread employed and of the material being sewn which have relevance for correct selection of a thread-tension value. As to the characteristics of the sewn fabric, the one of chief relevance is the thickness of the fabric, e.g., the thickness of several layers of sewn fabric. The generation of a clotch-thickness signal may be performed by a displacement transducer cooperating with the machine's cloth presser foot; when the presser foot is lowered into pressing engagement against the sewn fabric, the gap between the presser foot and the position it would occupy if no fabric at all were present is directly indicative of fabric thickness, and a displacement transducer for the presser foot can thus generate a signal directly indicative of cloth thickness. As to the characteristics of the thread employed, an important one is thread thickness, and a signal indicating thread thickness can be generated using an automatic thread-thickness gauge. However, equally important may be thread strength, not always to be simply equated with thread thickness, and also thread type, e.g., smooth such as to resist tensioning by tension disks 57 or rough such as to tend to be overly tensioned. If the thread-character signal is to be more than a simple thread-thickness signal, then use may, for example, be made of spools of thread provided on one axial end face with a standardized and machine-readable code number identifying a thread-character factor to be taken into account in the automatic selection of thread tension; this makes it unnecessary to use a separate thread thickness gauge, and furthermore makes it unnecessary for the operator to evaluate, subjectively or otherwise, the effect of a particular supply of thread upon the need for possible manual adjustment of automatically selected tension values.
The nominally-required-tension command signal, the character-of-thread signal, and the cloth-thickness signal are processed by calculator circuit 64 to yield at the output thereof an exactly correct tension command signal. The calculation of a correct tension command signal may be more or less simple. The cloth-thickness signal and the character-of-thread signal may, for example, be combined to form a corrective factor which is then applied to the nominally-required tension command signal from stage 62 to yield an exactly correct tension command signal. The combining of the cloth-thickness signal and character-of-thread signal to yield an appropriate corrective factor may be performed by actual computational circuitry, designed to derive the corrective factor in accordance with a preestablished, and empirically verified formula appropriate for a particular machine. Alternatively, instead of pure computation, circuit stage 64 might be mainly comprised of a corrective-factor memory, each of whose storage locations stores a respective corrective factor, with the value of the character-of-thread signal and the value of the cloth-thickness signal each serving to form part of the address of one of the storage locations of such corrective-factor memory; e.g., if the character-of-thread signal has a value within a particular one of, for example, ten different ranges of values, and if the cloth-thickness signal has a value within a particular one of, for example ten different ranges of cloth-thickness values, these two ranges in conjunction can directly constitute an address signal addressing a storage location which stores the corrective factor appropriate for that particular combination of values of the character-of-thread signal and the cloth-thickness signal. It will be appreciated that, among designers of tension-control systems, the thread-tension values appropriate for differing combinations of thread thickness and type and fabric thickness are readily ascertained. Actually, however, it is likewise within the skill of the art to apply empirical formulas interrelating character of thread, fabric thickness and interstitch distance, so that in general circuit stage 64 may, quite appropriately, be designed as an actual special-purpose calculator circuit, i.e., not merely be an addressable storage storing corrective factors such as just described.
In FIG. 9, subtractor 61 forms the difference between two signals, one indicating the commanded pressing force with which tension disks 57 are to be pressed together, the other being derived from pressure sensor 59 and indicating the force with which disks 57 are actually being pressed together, for negative-deedback control of disk-pressing force per se. However, instead of pressure sensor 59, use could be made of the angular-position transducer 100 of FIG. 6, to apply to the right input of subtractor 61 a signal indicative of the present angular position of output shaft 54, and thereby indicative of the present axially displaced position of stop member 55. Of course, in that event, the analog command signal applied to the left input of servo subtractor must be scaled in accordance with angular-position values of rotary transducer 100, i.e., instead of being scaled in accordance with disk-pressing force values per se.
In the embodiment of FIG. 9, the command signal applied to the left input of servo subtractor 61, indicative of the required value of disk pressing force or indicative of the required angular position of output shaft 54, is compared againt a feedback signal, the resultant error signal actuating adjuster motor 53. It will be appreciated, however, that the feedback branch from sensor 59 or from rotary transducer 100 could be eliminated, and the analog command signal produced at the output of converter 65 instead used to set the level of energization of the solenoid winding 10 of FIG. 1. Conversely, the command signal produced by the circuits of FIGS. 3, 5 and 6, used in those Figures for open-loop control current, could instead be applied to one input of a servo comparator, such as 61 in FIG. 9, the other input of the comparator receiving a feedback signal from, e.g., a pressure transducer such as 59 in FIG. 8.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of circuits and constructions differing from the types described above.
While the invention has been illustrated and described as embodied in automatic tension-control systems making use of particular tension-control mechanisms, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
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.
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The tension of the sewing machine's upper thread is varied automatically, in a variety of ways not requiring conscious participation on the part of the user of the machine. When one of a set of selectable stitch-patterns is selected by the user, an appropriate thread-tension value is automatically established, although the user retains the ability to adjust the automatically established tension value if he wishes. When the user swings the presser-foot lever of the machine up, to raise the cloth presser foot up from the cloth, e.g., for basting work, the thread tension is automatically lowered to a predetermined value suitable for basting, although still adjustable by the user if he thinks necessary. Where a stitch-pattern is implemented using an addressable ROM, tension command data for each stitch of the stitch-pattern may be stored in the ROM, for variation of thread tension from constituent stitch of the pattern to the next. Alternatively, the ROM stores no tension control data per se, and instead a calculating circuit calculates, from the mere stitch-control data presented by the ROM, distance-dependent values dependent upon the distances between successive needle-penetration locations of the stitch-pattern, and from those derives appropriate tension command signals.
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BACKGROUND
1. Field of the Invention
Implementations of various technologies described herein generally relate to packer cups for use in a wellbore.
2. Description of the Related Art
The following descriptions and examples are not admitted to be prior art by virtue of their inclusion within this section.
Packer cups are often used to straddle a perforated zone in a wellbore and divert treating fluid into the formation behind the casing. Packer cups are commonly used because they are simple to install and do not require complex mechanisms or moving parts to position them in the wellbore. Packer cups seal the casing since they are constructed to provide a larger diameter than the casing into which they are placed, thereby providing a slight nominal radial interference with the well bore casing. This interference, “swabbing,” or “squeeze,” creates a seal to isolate a geologic zone of interest and thereby diverts the treating fluid introduced into the casing into the formation.
Packer cups were developed originally to swab wells to start a well production. In recent years, packer cups have been used in fracturing or treatment operations carried out on coiled tubing or drill pipe. Such operations may require higher pressures and may require multiple sets of packer cups or isolations across various individual zones. At such high pressures, the rubber portion of the packer cups may deteriorate and extrude in the direction of the pressures, thereby jeopardizing the seal with the casing. Accordingly, a need exists in the industry for a system of packer cups that are capable of withstanding the high differential pressures encountered during fracturing or treatment operations.
SUMMARY
One embodiment of the present invention provides a packer cup system for use inside a wellbore comprising a packer cup and a backup component coupled thereto. The backup component further comprises a support member and a rubber ring disposed between the support member and the packer cup. The support member is configured to prevent the rubber ring from moving toward the support member.
Another embodiment of the present invention provides a packer cup system for use inside a wellbore comprising a packer cup and a backup component coupled thereto. In this embodiment, the backup component further comprises a support member and a wave spring disposed between the support member and the packer cup. The support member is configured to prevent the wave spring from moving toward the support member.
Still another embodiment of the present invention provides a packer cup system for use inside a wellbore comprising a packer cup and a backup component coupled thereto. The backup component further comprises a support member, a piston moveably disposed against the support member and a rubber ring disposed between the piston and the packer cup. The piston is configured to move between the support member and the rubber ring.
Yet another embodiment of the present invention provides a packer cup system for use inside a wellbore comprising a packer cup and a backup component coupled thereto. In this embodiment, the backup component further comprises a support member, a piston moveably disposed between the piston and the packer cup, and a wave spring disposed between the piston and the packer cup. The piston is configured to move between the support member and the wave spring.
The claimed subject matter is not limited to implementations that solve any or all of the noted disadvantages. Further, the summary section is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description section. The summary section is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
Implementations of various technologies will hereafter be described with reference to the accompanying drawings. It should be understood, however, that the accompanying drawings illustrate only the various implementations described herein and are not meant to limit the scope of various technologies described herein.
FIG. 1 illustrates a schematic diagram of a formation interval straddle tool that may be used in connection with one or more embodiments of the invention.
FIG. 2 illustrates a cross sectional view of a packer cup system in accordance with one implementation of various technologies described herein.
FIG. 3 illustrates a cross sectional view of a packer cup system in accordance with another implementation of various technologies described herein.
FIG. 4 illustrates a cross sectional view of a packer cup system in accordance with yet another implementation of various technologies described herein.
FIG. 5 illustrates a cross sectional view of a packer cup system in accordance with still another implementation of various technologies described herein.
FIG. 6 illustrates a cross sectional view of a packer cup system in accordance with still yet another implementation of various technologies described herein.
FIG. 7 illustrates a cross sectional view of a packer cup system in accordance with still yet another implementation of various technologies described herein.
FIG. 8 illustrates a cross sectional view of a packer cup system in accordance with yet another implementation of various technologies described herein.
DETAILED DESCRIPTION
As used here, the terms “up” and “down”; “upper” and “lower”; “upwardly” and “downwardly”; “below” and “above”; and other similar terms indicating relative positions above or below a given point or element may be used in connection with some implementations of various technologies described herein. However, when applied to equipment and methods for use in wells that are deviated or horizontal, or when applied to equipment and methods that when arranged in a well are in a deviated or horizontal orientation, such terms may refer to a left to right, right to left, or other relationships as appropriate.
FIG. 1 illustrates a schematic diagram of a formation interval straddle tool 10 that may be used in connection with implementations of various technologies described herein. The straddle tool 10 is of the type typically employed for earth formation zone fracturing or other formation treating operations in wellbores. FIG. 1 illustrates the straddle tool 10 as being positioned within a cased wellbore 12 , which has been drilled in an earth formation 14 . The straddle tool 10 may be lowered into the wellbore 12 on a string of coiled or jointed tubing 16 to a position adjacent a selected zone 18 of the earth formation 14 . The wellbore 12 may be cased with a casing 20 , which has been perforated at the selected zone 18 by the firing of perforating shaped charges of a perforating gun or other perforating device, as illustrated by the perforations 22 .
Once the straddle tool 10 is in position adjacent the selected formation zone 18 , the straddle tool 10 may be operated from the earth's surface to deploy anchor slips 24 to lock itself firmly into the casing 20 in preparation for fracturing or treating the selected formation zone 18 . The straddle tool 10 may further include one or more packer cup systems 100 disposed on a mandrel 50 . Each packer cup system 100 may include a packer cup 26 and a backup component 110 . When pressurized fracturing or treating fluid is pumped from the earth's surface through the string of coiled or jointed tubing 16 and the straddle tool 10 toward the formation zone 18 , the pressure of fluid exiting the straddle tool 10 may force the packer cups 26 to engage the casing 20 at one or more treating ports 28 . The open ends 29 of the cup packers 26 may be arranged to face each other and straddle an interval 30 of the wellbore 12 between the packer cups 26 . Although FIG. 1 illustrates the straddle tool 10 without any other attachments, it should be understood that in some implementations the straddle tool may have other tools or components attached thereto, such as a pressure balance system, a slurry dump valve, a scraper and the like.
When the packer cups 26 have fully engaged the casing 20 , the formation zone 18 and the straddled interval 30 between the packer cups 26 will be pressurized by the incoming fracturing or treating fluid. Upon completion of fracturing or treating of the formation zone 18 , the pumping of fracturing or treating fluid from the earth's surface may be discontinued, and the straddle tool 10 may be operated to dump any excess fluid, thereby relieving the pressure in the straddled interval 30 .
In general, the packer cups 26 may be configured to seal against extreme differential pressure. The packer cups 26 may also be flexible such that it may be run into a well without becoming stuck and durable so that high differential pressure may be held without extrusion or rupture. As such, the packer cups 26 may be constructed from strong and tear resistant rubber materials. Examples of such materials may include nitrile, VITON, hydrogenated nitrile, natural rubber, AFLAS, and urethane (or polyurethane).
FIG. 2 illustrates a cross sectional view of a packer cup system 200 in accordance with one implementation of various technologies described herein. The packer cup system 200 may include a packer cup 226 having a metal support 220 attached thereto. Both the packer cup 226 and the metal support 220 may be coupled to the mandrel 50 . In one implementation, the packer cup system 200 may include a backup component 210 having a rubber ring 240 coupled to the metal support 220 . In another implementation, the rubber ring 240 may be supported by a support member 250 coupled to the mandrel 50 . The rubber ring 240 may be made from strong and tear resistant rubber materials, such as nitrile, VITON, hydrogenated nitrile, natural rubber, AFLAS, urethane (or polyurethane), high DURO and the like. The support member 250 may be permanently coupled to the mandrel 50 . It should be understood that in some embodiments, the support ring 240 can be coupled to the packer cup 226 by molding onto the packer cup 226 to form an integral component.
The backup component 210 may be activated as a differential pressure is applied across the packer cup 226 . Such differential pressure may be caused by the difference between the pressure of the treatment fluid against the open ends 29 of the packer cup 226 and the pressure inside the annulus 260 . This difference in pressure across the packer cup 226 may move the packer cup 226 along the mandrel 50 towards the lower pressure side, i.e., towards the left side of the packer cup 226 in FIG. 2 . As a result of this movement, the rubber ring 240 may be compressed and radially expand toward the casing 20 to close the annular gap 260 between the packer cup 226 and the casing 20 . In this manner, the backup component 210 may be used to prevent the packer cup 226 from extruding under pressure, thereby enabling the packer cup 226 to operate under a high differential pressure environment.
FIG. 3 illustrates a cross sectional view of a packer cup system 300 in accordance with another implementation of various technologies described herein. The packer cup system 300 may include a packer cup 326 having a metal support 320 attached thereto. Both the packer cup 326 and the metal support 320 may be coupled to the mandrel 50 . In one implementation, a backup component 310 may be positioned to support the packer cup 326 . The backup component 310 may include a support member 350 coupled to a rubber ring 340 having a helical spring 325 embedded along the circumference of the rubber ring 340 . In one implementation, the helical spring 325 may be covered with a wire mesh 330 , which may be configured to minimize the amount of rubber material entering into the helical spring 325 during its expansion. The helical spring 325 may be configured to be more elastic than the rubber ring 340 . It should be understood that in some embodiment, the rubber ring 340 having the embedded helical spring 325 (with or without the wire mesh 330 ) can be coupled to the packer cup 326 by molding onto the packer cup 326 to form an integral component. As mentioned above, the support member 350 may be permanently coupled to the mandrel 50 .
The backup component 310 may be activated by the differential pressure across the packer cup 326 . This difference in pressure across the packer cup 326 may move the packer cup 326 along the mandrel 50 towards the lower pressure side, i.e., towards the left side of the packer cup 326 in FIG. 3 . As a result of this movement, the rubber ring 340 may be compressed and the helical spring 325 may expand radially toward the casing 20 to close the annular gap 360 between the packer cup 326 and the casing 20 . In this manner, the backup component 310 may be used to prevent the packer cup from extruding under pressure.
FIG. 4 illustrates a cross sectional view of a packer cup system 400 in accordance with yet another implementation of various technologies described herein. The packer cup system 400 may include a packer cup 426 having a metal support 420 attached thereto. Both the packer cup 426 and the metal support 420 may be coupled to the mandrel 50 . In one implementation, a backup component 410 may be positioned to support the packer cup 426 . The backup component 410 may include a support member 450 coupled to a wave spring 470 . It should be understood that in some embodiment, the wave spring 470 can be coupled to the packer cup 426 by molding onto the packer cup 426 to form an integral component. The support member 450 may be permanently coupled to the mandrel 50 .
The backup component 410 may be activated by the differential pressure across the packer cup 426 . This difference in pressure across the packer cup 426 may move the packer cup 426 along the mandrel 50 towards the lower pressure side, i.e., towards the left side of the packer cup 426 in FIG. 4 . As a result of this movement, the wave spring 470 may be compressed and expand radially toward the casing 20 , i.e., its inside diameter (ID) and outside diameter (OD) may radially expand toward the casing 20 , to close the annular gap 460 between the packer cup 426 and the casing 20 . In this manner, the backup component 410 may be used to prevent the packer cup 426 from extruding under pressure.
FIG. 5 illustrates a cross sectional view of a packer cup system 500 in accordance with still another implementation of various technologies described herein. The packer cup system 500 may include a packer cup 526 having a metal support 520 attached thereto. Both the packer cup 526 and the metal support 520 may be coupled to the mandrel 50 . In one implementation, a backup component 510 may be positioned to support the packer cup 526 . The backup component 510 may include a support member 550 coupled to a wave spring 570 coupled to a rubber ring 540 . It should be understood that the wave spring 570 and rubber ring 540 can be coupled to the packer cup 526 by molding onto packer cup 526 to form an integral component.
The backup component 510 may be activated by the differential pressure across the packer cup 526 . This difference in pressure across the packer cup 526 may move the packer cup 526 along the mandrel 50 towards the lower pressure side, i.e., towards the left side of the packer cup 526 in FIG. 5 . As a result of this movement, both the rubber ring 540 and the wave spring 570 may be compressed and cause the inside diameter (ID) and outside diameter (OD) of the wave spring 570 to expand radially toward the casing 20 , thereby closing the annular gap 560 between the packer cup 526 and the casing 20 . In this manner, the backup component 510 may be used to prevent the packer cup 526 from extruding under pressure.
FIG. 6 illustrates a cross sectional view of a packer cup system 600 in accordance with still yet another implementation of various technologies described herein. The packer cup system 600 may include a packer cup 626 having a metal support 620 attached thereto. Both the packer cup 626 and the metal support 620 may be coupled to the mandrel 50 . In one implementation, a backup component 610 may be positioned to support the packer cup 626 . The backup component 610 may include a support member 650 coupled to a mandrel 50 . In one implementation, the support member 650 may be permanently coupled to the mandrel 50 . The backup component 610 may further include a rubber ring 640 having a helical spring 625 embedded along the circumference of the rubber ring 640 and a piston 655 disposed between the support member 650 and the rubber ring 640 . In one implementation, the helical spring 625 may be covered with a wire mesh 630 , which may be configured to minimize the amount of rubber material entering into the helical spring 625 during its expansion. It should be understood that the rubber ring 640 having the embedded helical spring 625 (with or without the wire mesh 630 ) can be coupled to the packer cup 626 by molding onto the packer cup 626 to form an integral component.
In one implementation, the backup component 610 may be activated by fluid pressure flowing through a slot 685 to move the piston 655 against the rubber ring 640 having the helical spring 625 embedded therein such that both the helical spring 625 and rubber ring 640 may expand radially toward the casing 20 , thereby closing the annular gap 660 between the packer cup 626 and the casing 20 . The fluid pressure may be generated by the treatment or fracturing fluid flowing from the surface through the tubing 16 .
The backup component 610 may further include a spring 670 configured to exert a predetermined amount of force against the piston 655 . As such, the piston 655 may have to overcome this force before the piston 655 can press against the rubber ring 640 and cause the helical spring 625 to expand radially. In this manner, the backup component 610 may be activated only when the force generated by fluid pressure communicated through the slot 685 and acting on the piston 655 is greater than the amount of force exerted by the spring 670 .
The backup component 610 may further include a holding pin 680 configured to prevent the packer cup 626 from moving toward the piston 655 . A shoulder 690 may also be provided to prevent the packer cup 626 from moving away from the piston 655 . As such, the packer cup 626 may be held stationary by the holding pin 680 and the shoulder 690 . Implementations of various technologies described with reference to the packer cup system 600 may reduce the likelihood the backup component 610 from being activated during a run in-hole operation.
FIG. 7 illustrates a cross sectional view of a packer cup system 700 in accordance with still yet another implementation of various technologies described herein. The packer cup system 700 may include the same or similar elements or components as the packer cup system 600 , except that the rubber ring 640 and the helical spring 625 have been replaced with a wave spring 720 and a rubber ring 740 coupled thereto. Consequently, other details about those same or similar elements may be provided in the above paragraphs with reference to the packer cup system 600 . When the backup component 710 is activated, the piston 755 presses against the wave spring 720 and the rubber ring 740 , causing the inside diameter (ID) and outside diameter (OD) of the wave spring 720 to expand radially toward the casing 20 , thereby closing the annular gap 760 between the packer cup 726 and the casing 20 . In this manner, the backup component 710 may be activated by pressure applied from the surface to prevent the packer cup 726 from extruding under pressure. It should be understood that the wave spring 720 and rubber ring 740 can be coupled to the packer cup 726 by molding onto packer cup 726 to form an integral component.
FIG. 8 illustrates a cross sectional view of a packer cup system 800 in accordance with yet another implementation of various technologies described herein. The packer cup system 800 may include the same or similar elements or components as the packer cup system 700 with the exception of the rubber ring 740 . Consequently, other details about those same or similar elements may be provided in the above paragraphs with reference to the packer cup system 700 . When the backup component 810 is activated, the piston 855 presses against the wave spring 820 , causing the inside diameter (ID) and outside diameter (OD) of the wave spring 820 to expand radially against the casing 20 , thereby closing the annular gap 860 between the packer cup 826 and the casing 20 . In this manner, the backup component 810 may be activated by pressure applied from the surface to prevent the packer cup 826 from extruding under pressure.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
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The present invention provides a packer cup system for use inside a wellbore comprising a packer cup and a backup component coupled thereto. In one configuration, the backup component further comprises a support member and a rubber ring disposed between the support member and the packer cup. The support member is configured to prevent the rubber ring from moving toward the support member.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to gloves for the human hand which are particularly useful in participating in activities which include the clinching of the hand for substantially long periods of time. More particularly, this invention relates to a glove specifically designed to provide expandable zones over the metacarpalphalangeal joints which allows for expansion of the glove at selected locations in both the horizontal and vertical plane.
[0003] 2. Description of the Related Art
[0004] Glove construction for protection of the human hand is well known. Moreover, gloves have been designed for specific uses and particularly for specific and various athletic activities. For example, U.S. Pat. No. 6,389,601, teaches a glove particularly for use as a batting glove in baseball and softball which includes padding over selected pulleys and tendons of the fingers to prevent injury when striking a ball with a bat, particularly an aluminum bat. U.S. Pat. No. 3,175,226, for example, teaches a dress glove construction which completely covers the fingers and includes resiliently expandable materials in selected areas to accommodate hands of different sizes. U.S. Pat. No. 5,345,609 teaches a glove which includes shock absorbing cells disposed at selected portions along the top of the glove and U.S. Pat. No. 5,790,980 teaches a glove with a foam pad in the palm portion of the glove. Other prior art references attempt to provide sport gloves for supporting and stabilizing the wrist and the hand.
[0005] In activities which require the clinching of the hand, such as the gripping of handle bars of a bicycle or a motorcycle or ski sticks in cross-country skiing, the hands and particularly the fingers may be clenched for long periods of time. Thus, it is important that the blood circulation in the hands and the fingers function comfortably. For example, U.S. Pat. No. 3,997,922, teaches a glove particularly for use in cross-country skiing which is provided with cuts along the knuckles with pieces inserted therein having a larger diameter in the longitudinal direction of the glove than the respective dimension of the cuts.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a glove which takes stress off selective parts of the human hand when the hand is in a clinching condition.
[0007] Another object of the present invention is to provide a glove that does not restrict the blood circulation in the hand and fingers when the hand, including the fingers, are in a clinched condition for extended periods of time.
[0008] It is even another object of the present invention to provide a glove for use in clinching handlebars of bicycles or motorcycles or ski sticks as well as clinching garden tools, golf clubs, steering wheels, and the like.
[0009] Even a further object of the present invention is to provide a glove that expands in both longitudinal and horizontal or lateral directions when the hand is a clinched condition.
[0010] More particular, the present invention provides a glove which has a first expandable zone disposed on the top portion of the glove for positioning over the metacarpalphalangeal joint center axis of rotation of an index finger and a second expandable zone disposed on the top portion of the glove for positioning over a metacarpalphalangeal joint center axis of rotation of a small finger. Even further, a third expandable zone may be disposed on the top portion of the glove for positioning over the metacarpalphalangeal joints center axis of rotation of the ring finger and the long finger.
[0011] Further objects and advantages of the invention will appear from the following description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A better understanding of the invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
[0013] FIG. 1 is a top view of a glove of a preferred embodiment of the present invention;
[0014] FIG. 1A is a bottom view of the glove of FIG. 1 ;
[0015] FIG. 2 is a schematic anatomical view of the bones of the right-side human hand showing the dorsal-side details;
[0016] FIG. 3 is a top view of a glove of FIG. 1 showing the dorsal-side details and overlaying the skeletal structure of a right-dorsal side human hand;
[0017] FIG. 4 is an enlarged sectional view taken along line 4 - 4 of FIG. 3 showing a selected location for one expandable zone in a preferred embodiment of the present invention;
[0018] FIG. 5 is a sectional view taken along line 5 - 5 of FIG. 3 showing a selected location for a second expandable zone of the glove of the preferred embodiment of the present invention; and,
[0019] FIG. 6 is a sectional view taken along line 6 - 6 of FIG. 3 showing a selected location for a third expandable zone of the glove of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] In FIGS. 1 and 1A , a preferred glove 100 is provided for either a right, left or both human hand(s) 10 , as desired. A glove 100 for a left hand 10 utilizes symmetrical placement of the elements, materials and thicknesses herein described.
[0021] As shown in FIGS. 1 and 1A , the preferred glove 100 is exemplified for the right hand. The glove 100 is provided with a top portion 112 for covering a back side of the hand 10 including a top side of elongated sections to receive a plurality of fingers therein and a lower portion 114 to over a palm side of a hand 10 including a bottom side of elongated sections to receive the plurality of fingers therein. The elongated sections are identified by numeral 102 for an index finger, elongated section 104 for a long finger, elongated section 106 for a ring finger, and elongated section 108 for a small finger. A thumb section identified by numeral 110 is also provided.
[0022] As best shown in FIG. 1 , a first expandable zone 128 is positioned vertically or longitudinally along a selected portion of small finger section 108 and a second expandable zone 130 is positioned vertically or longitudinally along a selected portion of the index finger section 102 . A third expandable zone identified by the numeral 132 is horizontally or laterally positioned over selected portions of the knuckle area of the long finger and the ring finger. Expandable zones may also be provided, such as those identified by the numerals 120 , 122 , 124 , and 126 , over selected joints of fingers 102 , 104 , 106 , and 108 , respectively. The expandable zones are generally prepared by cutting appropriate slits or openings at selected locations of the glove for the expandable zones and sewing in pieces of appropriate materials including elastic materials which yield upon bending of the glove. A preferred material for the expansion zones 128 , 130 and 132 include elastic materials such as, for example, 2-way SPANDEX® or LYCRA®. Moreover, the top portion 112 and the bottom portion 114 is usually made from a material which provides protection from abrasion and may be made of a cloth, a leather, or a synthetic material or the like.
[0023] FIG. 2 is a schematic anatomical view of the bones of a right human hand 10 looking at a palm 18 side. Shown are the radius 20 , ulna 21 , radiocarpal joint (RC) 23 , distal radio ulna joint (DRUJ) 22 , wrist 12 , thumb 64 , index finger 65 , long finger 66 , ring finger 67 , and small finger 68 . The carpus 69 comprises eight carpal bones, seven of which are shown in FIG. 2 and includes the hamate bone 71 with its hook-like protrusion, the scaphoid 24 and the lunate 25 . The thumb 64 is comprised of the distal phalanx 51 , the interphalangeal joint (I) 46 , proximal phalanx 41 , diaphysis of proximal phalanx 41 , metacarpalphalangeal joint (MCP) 36 , metacarpal 31 , and carpometacarpal joint (CMC) 26 . The index finger 65 is comprised of the distal phalanx 60 , distal interphalangeal joint (DIP) 56 , middle phalanx 52 , proximal interphalangeal joint (PIP) 47 , proximal phalanx 42 , metacarpalphalangeal joint (MCP) 37 , and carpometacarpal joint (CMC) 27 . The long finger 66 is comprised of the distal phalanx 61 , distal interphalangeal joint (DIP) 57 , middle phalanx 53 , proximal interphalangeal joint (PIP) 48 , proximal phalanx 43 , metacarpalphalangeal joint (MCP) 38 , metacarpal 33 , and carpometacarpal joint (CMC) 23 . The ring finger 67 is comprised of the distal phalanx 62 , distal interphalangeal joint (DIP) 58 , middle phalanx 54 , proximal interphalangeal joint (PIP) 49 , proximal phalanx 44 , metacarpalphalangeal joint (MCP) 39 , metacarpal 34 , and carpometacarpal joint (CMC) 24 . The small finger 68 is comprised of the distal phalanx 63 , distal inter phalangeal joint (DIP) 59 , middle phalanx 55 , proximal interphalangeal joint (PIP) 50 , proximal phalanx 45 , metacarpalphalangeal joint (MCP) 40 , metacarpal 35 , and carpometacarpal joint (CMC) 30 .
[0024] FIG. 3 shows details of a dorsal side of a glove 100 to cover a human hand 10 and is seen overlaying the skeletal structure and skin outline of a right-dorsal-side human hand 10 . The glove 100 has a plurality of finger elements, 102 , 104 , 106 and 108 , a thumb element 110 , a top portion 112 , and a lower portion 114 (See FIG. 1A ), wherein the finger elements 102 , 104 , 106 , and 108 cover fingers 65 - 68 respectively. The thumb element 110 covers a thumb 64 , and the top portion 112 covers a back side 16 of the hand 10 . The lower portion 114 (See FIG. 1A ) covers the palm side (not shown) of the hand 10 . An elastic band 90 is attached to the top portion 112 and to the lower portion 114 . The elastic band 90 includes a securing means in the form of a hook 92 and a loop 94 fastener for retention above a human wrist 12 .
[0025] Referring now to FIGS. 3 and 4 , the first expandable zone 128 is disposed on the top portion 112 of the glove 100 for positioning vertically or longitudinally over the metacarpalphalangeal joint 40 of the small finger 68 . The first expandable zone 128 is preferably of an elastic material, as noted previously, and is sewn into a slit in the small finger element 108 and has one terminating end below the mid-point of the metacarpal 35 of small finger 68 and a second terminating end above the mid-point of a proximal phalanx 45 of the small finger 68 . Preferably, the length of expansion zone 128 is from 1 to 3 inches below and above the center axis of rotation of the metacarpalphalangeal joint 40 .
[0026] Referring now to FIGS. 3 and 5 , a second expandable zone 130 is disposed on the top portion 112 of the glove 100 for positioning vertically or longitudinally over the metacarpahalphalangeal joint 37 of the index finger 65 . The second expandable zone is also preferably an elastic material and is sewn into a slit in the index finger element 102 and has one terminating end below the mid-point of the metacarpal 32 and a second terminating end above the mid-point of the a proximal phalanx 42 of the index finger 65 . Preferably, the length of expansion zone 130 is from 1 to 3 inches below and above the center axis of rotation of the metacarpalphalangeal joint 37 .
[0027] Referring now to FIGS. 3 and 6 , a third expandable zone 132 is disposed on the top portion 112 of the glove 100 for positioning horizontally or laterally over the metacarpalphanalgeal joints 38 and 39 of the long finger 66 and the ring finger 67 , respectively. The third expandable zone 132 is also preferably an elastic material and is sewn into a slit in the finger elements 104 and 106 . Third expandable zone 132 has one terminating side adjacent the distal ends of the metacarpals 33 and 34 of the long finger 66 and the ring finger 67 and a second terminating side adjacent to the proximal ends of the proximal phalanx 43 of the long finger 66 and the proximal phalanx 44 of the ring finger 67 . The third expandable zone 132 also has one terminating end adjacent to the metacarpalphalangeal joint 40 of the small finger 33 and a second terminating end adjacent to the metacarpalphalangeal joint 37 of the index finger 65 .
[0028] Referring back to FIG. 3 , expandable zones may also be provided at selected portions over other joints of the fingers. As shown in FIG. 3 , an expandable zone 120 is positioned over the center axis of rotation of the proximal interphalangeal joint 47 of the index finger 65 ; an expandable zone 122 is disposed over the center axis of rotation of the proximal interphalangeal joint 48 of the long finger 66 ; expandable zone 124 is disposed over the proximal interphalangeal joint 49 of the ringer finger 67 ; and, expansion zone 126 is disposed over the proximal interphalangeal joint 50 of the small finger 68 .
[0029] As noted hereinbefore, the materials of construction of the expandable zones is preferably an elastic material, such as, 2-way SPANDEX® or LYCRA®. Thus, when a hand is inserted into the glove and the hand is clinched around handle bars, ski sticks, or the like, the length of the upper side of the glove is increased due to the expansion of the elastic material covering the metacarpalphalangeal joints 38 and 39 and the width of the glove is also increased due to the expansion of the elastic materials in the expansion zones 128 and 130 .
[0030] The detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.
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A glove is provided to flex as the user clinches his fist. The glove is provided with expandable zones on both sides of the top portion of the glove. Two expandable zones are positioned over the metacarpalphalangeal joints of the one small finger and the index finger. A third expandable zone is positioned to overly the center axis of rotation of the metacarpalphalangeal joints of the long finger and the ring finger. Cooperating relationship between the three expandable zones allow for expansion of the glove, both longitudinally and laterally, over the metacarpalphalangeal joints of the hand.
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BACKGROUND OF THE INVENTION
The present invention relates to a pack for cylindrical, hamburger-type sandwiches. More generally, it relates to a pack for any rather compact food presented in a cylindrical shape and intended to be eaten in the pack.
The hamburger being the most popular cylindrical sandwich, the descriptions shall be based on the application to the wrapping of hamburgers, as the wrapping of hamburgers is a delicate operation, inasmuch as it deals with a soft, open and layered sandwich, with dripping sauces and greasy debris which can fall and soil the consumer's clothing if the hamburger is not systematically supported from beneath in its pack during the entire consumption time.
There are two principal known types of hamburger packs-one is a hinged box in the shape of double trays, generally of square cross section, with a snap-in locking system. Currently, for environmental reasons these packs are preferably made of a light-weight flat or micro-flute paperboard; these trays are preformed in an automatic gluing operation.
The hamburger is placed flat in the lower tray, and the consumer must bring it upright, requiring that he delicately slide the index and/or second finger of one hand between the hamburger and the bottom of the lower tray to lift the hamburger with his thumb, in a very uncomfortable gesture, just as uncomfortable as holding the same lower tray with the other hand to protect against spots during consumption, while the upper tray hinged on the lower tray may hit his face during the eating process.
Moreover, children tend to eat the sandwich outside the tray, thereby frequently soiling their clothing.
Other packs are merely very thin rectangular sheets of paper which are wrapped around the hamburger in the manner any flat cylindrical object is wrapped, by tucking the extending edges of the folded paper under the wrapped item.
In addition, there is a very thin, longitudinally pleated wrap, where the pleats are secured at the end by lateral seals, the paper having a polyethylene coating serving as a hot-melt glue to allow it to be sealed.
This manual pack is very difficult to adjust, it is rather unattractive once in place, and has not met with the expected success.
According to another method described in U.S. Pat. No. 4,189,054, a cylindrical box for the packing of round sandwiches consists of two half-shells, each surrounding the sandwich over half of its perimeter, and connected to each other along a single hinge parallel to the generatrix of the cylinder. In the closed position, each shell comes into edge-to-edge contact with the other. During the filling operation, the sandwich is placed upright into the lower shell, and the upper shell is lowered on the lower shell.
During consumption, the sandwich is held in the lower shell which can either be torn along its radius, or folded outward laterally along the hinge in the generatrix of the cylinder. This pack is produced by polyurethane foam molding and has several disadvantages. Since the peripheral and lateral walls are perpendicular to each other and molded, the packs are not stackable; the sandwich is too ensconced at the bottom of one shell while the other shell hits the consumer's face, which is most uncomfortable, particularly during the end phase of consumption as the radial tear-out of the half-shell as well as the lateral tear-out features provided to access the last portion of the sandwich with the mouth are awkward and require a strong pull on the pack which may suddenly give way and possibly dislocate the sandwich, and cause food scraps to shower on the consumer or his neighbors.
To our knowledge, this pack has never actually been used for these reasons.
Differently, U.S. Pat. No. 4,494,785 relates to a precut and prepleated flexible paper napkin destined to partially cover a cylindrical sandwich allowing it to be held in one's fingers without them touching the food. It consists of a strip partially surrounding the periphery of the sandwich and of two series of parallel two-by-two flaps designed to fit between the fingers and the top and bottom of the sandwich respectively. This napkin stays around the sandwich only if it is held by the hand, and does not allow to effectively catch the sauce or greasy scraps escaping from the sandwich during its consumption, nor does it provide for thermal insulation of the hot sandwich.
The very old, German patent 336789 describes a rectangular parallelepiped box with square cross-section and cross-bottom closure obtained through the diagonal folding of the four bottom fields; this box is accessible from the bottom only; it mainly serves to wrap powdered or grain products, and possesses no specific characteristic for eating a round sandwich in its pack, even if one box may serve many different purposes.
U.S. Pat. No. 2,443,531 describes an hermetically sealed cubic box of rather thick paperboard, specifically designed to accommodate a cube of ice cream to be carried under the best possible conditions (mainly of temperature) between the point of purchase and the point of consumption.
The paperboard sheet is divided into equal square areas along three longitudinal strips, delimited by two parallel fold lines and five transversal strips delimited by four fold lines perpendicular to the former.
To consume the content, the box is placed on an horizontal table and redeployed in the plane of the table so that the ice cream remains on the central square area on which it can be cut and served. Granted perhaps that this box may accommodate a hamburger in a specific application, one cannot help but realize that it has not been designed for a hamburger to be eaten in its pack.
The round box disclosed in U.S. Pat. No. 2,224,504 consists of a cylinder made from a sheet of unspecified material, having a central section and lateral extensions, the length of which is exactly half the diameter of the product to be packed.
It is the material of these extensions which, by folding down on both sides of the apertures of the central cylinder along fan-shaped pleats, closes the cylinder and wraps a product compatible with this type of pack which can be opened from either side. The resulting pseudo-box possesses no useful characteristic for a hamburger pack, much less for the consumption of a hamburger from the pack as it does not have a stable sealed bottom.
As we know, it is designed to package deluxe soaps and other perfume items or gifts, preferably having two roughly parallel planes.
The paperboard container described in U.S. Pat. No. 2,295,508 forms a universal box with original assembling and locking, designed to hold fairly large volumes, but as a result has the usefulness of any non-specific traditional box, which was actually the inventor's intent as he was seeking the widest possible application as stated in the text of the patent.
The paperboard container in U.S. Pat. No. 3,031,124 features a very complicated manual folding system in no way suitable to large commercial preforming runs; while the esthetic result is quite pleasing, this satchel shaped pack does not offer any specific application, which was the intent of its inventor. In another perspective, had this pack held any specific interest for the consumption of a hamburger, surely this would have become known since 1959.
In 1963, U.S. Pat. No. 945,399 describes a wrapping process for various articles with a folded sheet, lined or impregnated with polyethylene in particular, but also with aluminum, and especially a means to utilize the lining material to heatseal the organized pleats and seal the pack through the application of a rigid thermoplastic label made from a compatible material and designed to display a brand name outside the pack.
We are far removed here from the concern for a specific hamburger pack.
The analyses of all above-mentioned packs and of many other existing food packs leads to the conclusion that while some of them may be used for a hamburger, none of them, including the currently used hinged boxes and the lined papers, offer nor do they claim to offer all of the required specifications allowing the easy and practical consumption in its pack of a hamburger or another compact food of cylindrical shape.
SUMMARY OF THE INVENTION
The following presentation of the Invention demonstrates that it uses different means for different functions and results, both compared to the currently known and used hamburger packs as well as compared to the disclosures of previously analyzed patents, which do not suggest, individually or in combination, the subject of the Invention; consequently, since the Invention, particularly in its third version, belongs to a special technical category, the man of the art could not be tempted to seek and to choose the disclosures of said patents to realize the Invention.
In its basic version, this invention concerns a first, flat pack, quickly assembled and locked for cylindrical, hamburger type sandwiches and other similar food. A second version of the invention consists of two half-shells, manually preformable, with ultra-rapid assembling-locking once preformed, with limited stackability. In a second variation, the pack is made of two half-shells, preformable on automatic machines directly into a stacking position. The packs can then be inverted into a manual filling, assembly and locking position, specifically designed for professional use (particularly at rush hour in fast-food restaurants).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a blank from which a pack in accordance with one embodiment of the present invention may be formed.
FIGS. 2-6 are isometric views showing the folding sequence of the blank of FIG. 1 to form a completed pack.
FIG. 7 is a top plan view of a blank from which a pack in accordance with an alternate embodiment of the present invention may be formed.
FIGS. 8-9 are isometric views showing the locking sequence during formation of the blank of FIG. 7 into a completed pack.
FIG. 10 is a top plan view of a blank from which a pack in accordance with a further alternate embodiment of the present invention may be formed.
FIGS. 11-12 are isometric views showing the locking sequence during formation of the blank of FIG. 10 into a completed pack.
FIG. 13 is an isometric view of the pack formed from the blank of FIG. 1, showing the pack opened for consuming the packaged sandwich.
FIG. 14 is a top plan view of a blank from which a pack in accordance with a further alternate embodiment of the present invention may be formed.
FIGS. 15-16 are isometric views showing the folding sequence during formation of the blank of FIG. 14 into a completed pack.
FIG. 17 is a top plan view of a blank from which a pack in accordance with a further alternate embodiment of the present invention may be formed.
FIG. 18 is a top view of a preformed, collapsed pack formed from the blank of FIG. 17.
FIG. 18A is an isometric view of the collapsed pack of FIG. 18, erected to receive a sandwich to be packaged therein.
FIGS. 19-20 are isometric views showing the folding sequence during formation of the blank of FIG. 17 into a completed pack.
FIG. 21 is a top plan view of a blank from which a pack in accordance with a further alternate embodiment of the present invention may be formed.
FIGS. 22-23 are isometric views showing the folding sequence during formation of the blank of FIG. 21 into a completed pack.
FIG. 24 is a top plan view of a blank from which a pack in accordance with a further alternate embodiment of the present invention may be formed.
FIGS. 25-26 are isometric views showing the folding sequence during formation of the blank of FIG. 24 into a completed pack.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a top view of the core concept of the Invention, purposely presented for the construction of a pack with regular hexagonal cross-section, as on the one hand, it allows the optimal reading of the figures, and on the other hand, it is one of the preferred embodiments of the Invention.
The thin sheet material used could preferably be a thin paperboard or microflute, grease-proofed in its thickness or at least on its internal surface, completely recyclable, and weighing between 180 and 250 grams per square meter.
A pack according to this basic version is obtained by cutting a suitable area (with a minimum of scraps) using a flat die applicable under pressure. This area resembles a stretched rectangle.
The blank can also be obtained from a paperboard roll cut during unwinding.
The scores marking the beginning of the pleats are obtained by means of a non-cutting tool attached to the cutting tool, and capable of imprinting on each side of the paperboard an indentation along various lines representing fold lines.
The fold lines shown in full lines (a) on FIG. 1 define groups of outward pleats.
The fold lines shown in broken lines (b) on FIG. 1 define inward or support pleats.
FIG. 2 takes FIG. 1 after the first folding. It shows that two strips A and B are symmetrically arranged around a strip C to form the pack.
Shown in the horizontal on this strip C, the width (e) of which corresponds to the thickness of the hamburger (S) to be packed, is an internal panel (1) designed to receive the hamburger vertically. This panel is the pivotal panel of the system; the wrapping panels (2), (3), (4), (5), (6) and (7) have the same dimensions as panel (1) in this regular hexagonal presentation.
Once the hamburger is placed on the pivotal panel, it is held in this vertical position by bringing back toward the hamburger with the thumb and index of one hand the two opposed symmetrical panels (f) (on strips A and B) FIG. 1.
In this basic version the height (r) of strips A and B (and, therefore, of panel (f)) is preferably equal to the radius of the hamburger to be packed.
With the other hand sliding under the pack and raising the integral panels (7), (6) and (5) FIG. 1, the type (b) inward pleats form naturally toward the inside of the pack and symmetrically on each strip A and B, and come to rest on the hamburger and tighten around it. The function of pleats (b) here is essential.
The lateral and symmetrical panels (8) which are of a height (h) slightly greater than (r) consolidate and stabilize this tightening by the penetration of their extending tab (o) between the panel (f) and the hamburger, this being the first step of the wrapping process of (approximately) two-thirds of the volume of the hamburger.
The wrapping action of the last third is done by laterally holding between the thumb and index finger of one hand the thus obtained fixed structure delimited by panels (1), (5), (6) and (7), integral with each other, and with the other hand raising panels (2), (3) and (4) FIG. 3, thereby forming and setting the corresponding inward lateral pleats resting against the hamburger which, at the end of wrapping, brings panel (4) to completely cover panel (7) FIG. 4 to achieve an absolutely compact assembly needing only to be locked.
Several solutions may then be envisaged: the most immediately apparent is to fold over the symmetrical triangles (9) of panels (18) located on both sides of panel (4) behind the pleats (t) of panels (8) respectively; FIG. 4 shows in a dotted line (10) the folding of triangle (9) behind the pleat (t) of one panel (8).
The wrapping and locking operation occurred without panel (1) ever leaving its original position on the horizontal plane where the wrapping process normally takes place, and the hamburger has remained completely immobile during the 4 to 5 seconds the operation lasted, before being returned to a flat position in its pack and on its base to preserve its integrity.
FIGS. 1 to 20 show a pack structure of regular hexagonal cross-section, the diameter of the hamburger being approximately that of the circle inscribed inside the hexagon.
Pack structures of square or pentagonal cross section or any other, preferably of polygonal cross section are possible.
However, the regular hexagonal cross section design turns out to be the best as the volume loss in the six 120° angles is only slight, the useful length of the blank is economical compared to packs of pentagonal or square cross section which are discussed later, and finally, as in the latter packs, the number of lateral pleats is perfectly controllable during forming and affords a tight fit.
In addition, the hexagonal and pentagonal packs have a pleasing appearance.
From the heptagonal cross section to the geometric limit of the circle cross section, the disadvantages of this basic concept of the Invention mostly stem from the difficulty of organizing the too numerous support pleats and outward pleats.
FIG. 5 shows an adhesive patch (14) glued on to reinforce the tucked-in pleat lock (10).
FIG. 6 shows a glued adhesive patch (14) as the sole lock, the pleat (9) being completely eliminated here during diecutting of the paperboard.
As explained earlier, the symmetrical arrangement of the pack around the pivotal panel (1) implies that the lateral panels (f) which are symmetrical in relation to panel (1) are each limited by two inward pleats of type (b) and two outward pleats of type (a) designated by (p) on FIG. 1 and FIG. 7. Once the pack is formed, both pleats (p) can be used as the female anchoring elements for an interesting lock design.
In FIG. 7, panel (4) and panels (15) symmetrical in relation to (4) show cut anchors (16) having hinges (w) securing them to these panels (15).
These anchors which are the male elements of this locking system, can be punched toward the outside of the pack (FIG. 8), and folded over their hinges (w) in such a way that the tips of each anchor are capable of locking the pack by sliding behind the external pleats (p) symmetrical to each other in relation to panel (f).
This lock, which is shown in FIG. 9, is easy to achieve as well as effective.
FIG. 10 shows a wide tab (19) cut out from panel (18), hinging on that panel, and catching at (20) behind the external pleat (t) of panel (8). This catch is facilitated by a cutout (21) allowing the lock shown in FIG. 11.
This tab lock is the fastest to implement, and its strength can be insured by optimizing the tab (19). It is the preferred lock of the Invention in this basic version, preferably in its various regular polygonal cross sections.
Similarly for the lock also shown in FIG. 10 by the tab (23) cut out on panel (22), hinged on this panel and catching in (24) behind the external pleat (t) of panel (8), the catch is facilitated by a specific cut-out (25) allowing the lock shown in FIG. 12.
The difference between the lock in FIG. 11 and that in FIG. 12 resides only in the fact that the tab (23) is inside panel (22) and not outside as shown in FIG. 11.
The tab (23) is better integrated into the pleasing appearance of the pack, although its implementation, while easy, is less immediate than that of the tab (19) which remains preferred due to a better locking time.
FIG. 2 shows on each side of panel (1) and originating from panels (f) two cutouts (12) symmetrical in relation to (f) and held back by limit points (13) at the edge of strips A and B. When the limit points (13) are popped by pulling the panels (f) toward the outside of the pack, two symmetrical cut-out areas (11) are then delimited and held in an external hinge on panels
Upon opening the pack FIG. 13 and popping the limit points, the lip-shaped areas (11) retract (or cut out) to allow total comfort of consumption, as the hinge is parallel and close to the pleat between (f) and (1).
In addition, to insure total comfort, one simply tightens with the thumb and index finger of each hand the strips A and B on each side of the hamburger so it is securely held with the four fingers on the pivotal panel (1) while biting into the hamburger.
According to whether one starts eating an almost whole hamburger or finishes eating it, the pack can be increasingly deployed for utmost eating ease and finally, after consumption of the hamburger, the pack can be crushed and tossed at a location where it is picked up for recycling (this location is generally provided in fast-food places).
So far the description covered a flat generic pack and its folding system with a number of variables allowing different types of locks that are easy to achieve and all quick locking, with a preference for the tab (19) FIG. 10, more efficient in actual assembly time.
It is now proposed, starting from this basic version of an initial flat pack, to advance, in a first evolution, to a second pack which, once manually formed, is particularly quick to assemble and lock. This requires the manual preparation in hidden time (or preferably in idle time), starting from a pack such as shown in the flat in FIG. 14, of two preformed half-shells (FIG. 15) which, once the hamburger is placed on the pivotal panel (1) (vertically if the pack is open toward the top in an horizontal balance, or horizontally if the pack is lying on a plane and open horizontally) can be folded over each other, with panel (4) covering panel (7) or vice-versa.
Compared to FIG. 1, FIG. 14 is totally symmetrical in relation to its central strip including panels 1 to 7 and to the strip perpendicular to it including panel (1) panels (f) and lips (11) hinging on (f).
As can be seen in FIG. 14, the panels (26) have been troncated from triangle (9) FIG. 1, and are now devoid of any fold line.
However, the panels (27) have two outward pleat lines (u) and two inward pleat lines forming rectangles triangles sic! (28) and (29).
FIG. 15 shows in a lateral view how it is possible, starting with the folds in FIG. 14 to form two symmetrical half-shells shown by the visible external panels (26), (27), and (30).
The external panel (27) hides the two folds (28) and (29) set one on top of the other behind the panel (27) inside the pack so that a simple fastening in area (31) can lock together from the inside the external panels (26), (27) and (30) to achieve a perfectly shaped and strong half-shell.
The other half-shell is obtained in the same manner.
The fastening can be traditional, but considering the application, it is best to consider a fastening through punching/embossing, thus eliminating any metal staples and permitting the inclusion of a logo or a stamped-on brand.
This type of fastening can be done by a commercially known device.
Once the assembly consisting of the two half-shells is obtained, the hamburger is quickly introduced against the pivotal panel (1), and the assembly is locked by bringing together with a slight pressure of both hands the two half-shells which come down one on top of the other to counter the tension effect created by the setting up of the external (moveable) pleats on the internal (fixed) pleats around the hamburger on each side of panels (f).
Generally, no further locking is required if the proper light weight board has been selected, in the correct caliper and grade for best temperature and even humidity resistance if the humidity is of a nature to soften the pack and harm its lock.
FIG. 16 shows FIG. 15 after the folding down of one half-shell.
In addition, in the regular hexagonal configuration the packs with preformed half-shells FIG. 15 are stackable.
However, stacking here presents two major problems:
first, it must be achieved under vertical pressure as these packs to be stacked horizontally on top of each other have two symmetrical concavities each consisting of the two half-shells, which may cause distortions in the pack beneath.
Secondly and consequently, the number of stackable units is very small because in this doubly-concave and almost vertical configuration the saturation point is quickly reached.
Consequently, to eliminate the aforementioned problems and primarily to achieve unlimited stackability of the packs, it is necessary, as shown in FIG. 17 in a variation of FIG. 14, to cut the blank in a manner allowing the commercial production of a third optimally used double-tray pack, which is immediately facilitated by the fact that this double tray already has four oblique panels radially opposed two by two, and that the bottoms are narrower than the openings.
This embodiment, which is evolved from the preceding fastened manual design, is by far the most important of the Invention from the standpoint of large commercial applications.
During commercial production of these double trays under the Invention, the sides (j) of (32) and (33) of the blanks FIG. 17 (which are fed in series into an automatic machine called a tray former well known to professionals) are glued edge to edge on the internal panel (27) of the pack along height (k) of (27), preferably so that the internal lateral panels of the shells are completely lined by the panels set in during the gluing operation.
This results in the formation, by observing several technical requirements which are described hereinafter, of two attached half-shells, symmetrical in relation to panel (1) which has become the upper plane of the assembly (FIGS. 18 and 18A), both attached half-shells (or trays) hinged on the pivotal panel (1) resting in the horizontal on the outside planes of their two panels (6) and (3) respectively.
FIG. 18 is a top view of the assembly consisting of the two trays symmetrically organized in relation to panel (1), panel (1) being contiguous to each panel (34) (extrapolated from panels (f) of FIGS. 1 and 2) symmetrical in relation to panel (1), each panel (34) having a lip (11), also extrapolated from the figures on the preceding sheets, which can be moved inside or outside the pack along a groove or a horizontal perforation (m) located slightly above the base of the pack; the outward retraction of the opposing two lips (11) is provided to facilitate the full consumption of the sandwich (S).
It is necessary now to explain the technical requirements enabling the commercial tray-forming on an automatic machine achieving the result shown in FIG. 18A, i.e. a double tray resting horizontally on its panels (3) and (6), and having panel (1) as its upper plane:
The first requirement is the proper reduction in the size of the outward (a) and inward (b) pleats, delimiting, after their reduction, two small triangles (v) at both ends of each hinge between panel (1) and (2) and panel (1) and (5), the small pleats (b) being located two by two in the extension of each of the two above-mentioned hinge pleats.
This reduction in size of the pleats (a) and (b) is necessary to avoid distorting and thus tearing the thin paperboard sheet during the forming process, when pressure-gluing the tray on the machine, which would occur if (a) and (b) were kept in their original size (FIG. 1).
Stacking is made possible here through the tensioning which occurs in the tray-forming process when gluing the small pleats (a), which causes a stable elastic, outwardly-rounded distortion of the half-shell corners along the pleats between panel (5) and panels (33) contiguous to (5) and along the pleats between panel (2) and panels (33) contiguous to (2) (FIG. 18).
When producing a tray with a well defined paperboard, the optimum length of a pleat (a) is that which allows to maintain the stable elastic distortion of the tray on both sides adjacent to its pivotal pleat with panel (1) without tearing the paperboard in the area where the outside ends of the pleats (a) meet the outside edges of the tray.
It is this stable elastic distortion which keeps the lateral panels of the half-shells flaring outward (the bottom of the half-shells is far narrower than the opening), and which allows them to be stacked at the end of the production cycle.
The thus fabricated pack can then, as explained hereafter, go from a stable stacking configuration to a stable filling configuration of the pack with the sandwich, and then to a stable closed configuration.
Starting from the stable stacking configuration, panel (1) and lateral panels (2) and (5) are roughly perpendicular one to the other two, and the passage to a stable filling configuration is possible only if pressure is exerted on each half-shell by bringing together (preferably at the same time and with both hands) panel (4) with panel (2) and panel (7) with panel (5) (FIG. 18A) and making them pivot upward each on its hinge pleat with panel (1) until the tension of pleat (a) is cancelled at the same time as the adjacent panels (5), (1) and (2) are positioned in the same plane, this plane assuming the role of swing plane of the pack to change configuration.
A return from the filling position to the stacking position is of no operational interest since the consumer will not have to do it.
But this is obviously feasible by doing the reverse motion which results in forcing the pleats (a) to be re-tensioned.
Technically speaking, the small moveable pleats (a) are the primary active element of the pack.
Their tensioning or untensioning is key to the passage of the pack from one major state (stacking position) to another major state (filling position), which we shall call the inverting of the pack (in one direction or another). In addition, they insure the stability of each of these major states, the equilibria of which can only be interrupted by constraint.
Filling of the pack is easy as it suffices to introduce the sandwich, on its edge against panel (1), either vertically or horizontally on a work plane, and to close it by bringing one half-shell into the other, by pivoting on the hinge pleats of panel (1). With this motion, the free lateral lips (11) FIG. 17, adjacent to panel (1) penetrate easily inside each half-shell above and below the sandwich. The pack is completely closed when panel (4)is perfectly superposed on panel (7).
The sandwich is then enclosed and thermally insulated until it is consumed.
During consumption, the half-shells are simply spread apart from each other and the sandwich appears on its edge against panel (1). It is comfortably held in the pack by finger pressure on both sides of the lateral lips (11).
The lips (11) are folded back outward without brusque motion when the mouth must reach the last portion. The pack has thus prevented to the very end any sauces spills, held back greasy food scraps and retained its initial attractive shape.
A second technical requirement of the pack is that in order to even better prevent any tearing of the thin paperboard sheet during tray-forming, particularly in the area of the small pleats (a) and (b) (especially during automatic high-speed production), it is very important that the four small triangles (v) on each side of (34) between the pleats of optimally reduced height (a) and (b), offer the best possible resistance to tear through the inclusion of spokes (g) and (d) respectively in the outer corners of the reduced size pleats (a) and (b) with the third side of triangle (v); these spokes are designed to eliminate the starts of any tears which are always possible when thin blanks, precut to an appropriate planned size have acute corners subject to stretches, pulls or pressures during trayforming.
But tray-forming per se is not the only cause of possible tear of the pack FIGS. 17 and 18 in the area of the small triangles (v):
Indeed, the sandwich (S) wrapping process per se starts with the manual setting up of the pack in the inverting operation described above, whose notable effect is that panels (5), (1) and (2) in that order return to the same plane in a stable configuration which is the hamburger filling configuration.
This manual inverting which takes less than a second (at the time of use or eventually in advance) causes the resetting into spring pleats of the four gussets delimited by the small triangles (v) tensioned earlier during tray forming.
It is clear then that the spokes (d) and (g) play an important role in the tear resistance at the time of manual inverting of panel (1), resulting in the pseudo verticalization of the two half-shells, with openings face to face, if by chance this inverting were to occur in a rough manner.
It is found, however, that in actual use the pack still retains sufficient spring action when a pleat (a) is torn on either tray, even if a pleat (a) is torn on each of them.
It should be pointed out that the polyethylene-lined paperboard packs provide perfect tear resistance both during tray-forming and manual inverting.
As another consideration, it should be noted that the wet heat released by a hot sandwich especially inside a pack such as described in FIGS. 15 and 19 has a natural tendency to soften the walls of said pack and to weaken its lock in particular, if such lock is not strong enough but without impeding the easy opening at the time of consumption of the sandwich.
There are many locking possibilities, but in the regular hexagonal design of FIGS. (17), (18) and (18A) preference shall be given to a lock securing the outside of panel (7) under the inside of panel (4), (or conversely) the inside of panel (7) under the outside of panel (4).
Of necessity, the chosen system shall not hinder the forming of the trays particularly in high-speed automated production.
FIG. 17 shows in the extension of the center of panel (7) a tab (z) in the shape of a rounded arrow with spurs (q) and (q') located on a line parallel to the outside edge of panel (7), separated by a distance (n); the segment common to the tab and the outside edge of panel (7) is of a size (L) slightly smaller than (n).
In the thickness of panel (3) and contiguously to the pleat of panel (3) with panel (4), a rectangular slot (y) approximately 1 to 2 millimeters wide and of length (L) is provided in the center area of the abovementioned pleat in such so that after the introduction of the sandwich into the pack, at the locking time the tab integral to one of the two half-shells can be snapped into slot (y) of the other half-shell under light pressure considering that (L) is slightly larger than (n); (4) then covers (7) perfectly.
The pack is very easily opened at the proper time by a slight outward pull to uncouple the shells.
Note that between line (q) (q') and the outer edge of panel (7) there is located an isosceles trapeze of large base (n), of small base (L), the height of which must be in approximate relation of one millimeter for a pack made from a thin sheet of about 2 to 3 tenths of a millimeter; the selection of the isosceles trapeze affords the possibility of a self-adjusting lock on the oblique sides of the trapeze.
It should further be noted that the panels (34) with the lips (11) can be of different design than those on FIGS. (17) and (18). The requirements here are:
First, the height of panel (34), lip (11) included, must be greater than the radius of the sandwich (S) so that once the pack is closed over the sandwich, the panel (34) does not allow partial visibility of the sandwich toward the center of the pack, but rather that it protects the sandwich up to above its diameter.
The second requirement is that the pack must also be perfectly enclosed laterally to insure the best temperature retention prior to consumption, particularly in the case of hot and wet sandwiches.
In FIGS. 17, 18, 18A, 19, 20, the sides of panels (34) have been suggested in the extension of the pleats (a) for easier reading of the figures; obviously, the opposing panels (34) can each be extended on both sides toward the lateral panels (33) (FIG. 19) within a maximum limit of two symmetrical sections (x), inasmuch as these equal sections added on both sides of (34) are completely detached from panels (33) as well as from the triangles (v) to allow the working of the spring gussets between the pleats (a) and (b).
In FIG. 19 which shows a major practical embodiment, the hinge (m) of the lip (11) is ideally located between the two tops (35) of pleats (a) on both sides of hinge (m); the segments (36) are cut out to allow the wings (x) of (34) to penetrate inside the shells at the time of closing of the pack and especially to allow the spring gussets between (a) and (b) to function freely.
The advantage of having larger panels (34) is, first of all, a better grip on the sandwich between the thumbs and index fingers of both hands by permitting a greater spread between them; next, better protection against dripping sauces, especially at the beginning of sandwich consumption; lastly, in the case of a pack which the restaurant can use either vertically or horizontally flat on a preparation counter, it is desirable that the sandwich (S) does not touch the counter, which could occur in the horizontal use prior to closing the pack in case of too wide openings between the panel (34) and the contiguous panels (33).
FIGS. 21, 22 and 23 show a pack according to the last type, capable of being commercially produced, but of regular pentagonal cross section.
It includes seven wrapping panels for five cross section sides, meaning that its locking principle involves four panels in two-by two's (panels (6'), (4'), (7') and (3')).
Indeed, when this pack is closed after the sandwich is placed on panel (1'), the inner side of (6') is perfectly superposed to the outer side of (4'), while in the same motion the inner side of (7') is perfectly superposed to the outer side of (3').
The closure can of course occur in the other direction.
In this pack of (preferably) regular pentagonal cross section, locking occurs naturally through the superposition of the (108°) angle between panels (3) and (4) on the (108°) angle between panels (6) and (7) at the end of wrapping, while allowing easy unlocking.
To economize paperboard, i.e., to use a shorter precut blank, the sections outside line (A1) (B1) on panel (7') and line (A2) (B2) on panel (4 ') can be eliminated. These sections are hatched on FIGS. 23 and 24.
FIGS. 24, 25 and 26 also show a pack according to the last type, capable of being commercially produced, but of square cross section.
This pack includes five wrapping panels for four cross section panels, which implies a lock of the same type as for the pack of hexagonal cross section after perfect covering of external panel (5") by the internal panel (3") or vice-versa (FIG. 26).
It could be assumed that the stacking of this square pack is self-evident and does not necessitate the inverting technique after tray-forming. In actual application, it is found that the direct stacking of parallelepiped packs having as a base the sum of the contiguous panels (4"), (1") and (2") quickly reaches saturation unless the packs are flared, which would negate any covering of the panels (5") and (3") after wrapping, as these panels then present isosceles trapezes opposed by their large bases.
When creating round sandwich packs, the man of the art (upon precise analysis of the previously known art) does not seem to have made it his major concern to design a product precisely suited to the consumption of a hamburger or other foods of that type and shape, by considering all the consumer requirements as well as the needs of professionals (of the fast food restaurants in particular).
For consumers, the specific pack must be practical, since the sandwich is to be eaten in its wrap to avoid dripping sauces. The pack itself must invite them to do so naturally by its very configuration and should somehow suggest to the consumer that any other approach is excluded.
The consumer's comfort surely is not served when a hamburger is served in a rectangular box which does not present any notable features meeting the practical needs inherent to the consumption of a hamburger in its pack.
Comfort is also non-existent when the hamburger is offered in a pack made of two half-shells assembled on a single hinge as the sandwich is ensconced at the bottom of one half-shell with the all the unpleasantness already described.
Conversely, it is indeed comfortable when the sandwich, which is located on the wide hinge plane of the two easily unlocked half-shells, is easily accessible to the mouth and can be firmly held between thumbs and index fingers of both hands when bitten into, and at the appropriate time, the lateral lips of the pack fold back gently to allow the total consumption of the sandwich.
As far as the professional user is concerned, the Invention makes available to him an evolvable pack which he adjusts to his needs. If he manages a small restaurant, he can use the first or second pack, the shells of which can be formed ahead of time or in hidden time. If he operates a larger fast food restaurant, he will preferably use the third, stackable pack, of a slightly higher purchase price because it is immediately usable, although at a fairly low commercial series price.
The professional of a large (fast food type) restaurant will appreciate the image enhancement provided by the distinctive, omnipresent packs and the simple inducement to consumer loyalty generated by a clear improvement of his service to the consumer.
He will recognize in the Invention the answer to the complex problem posed by the inverting system of the double tray prior to its use, because of the kitchen counter space savings provided by the stackable packs.
It should be kept in mind that the inverting system under the Invention exceptionally allows the commercial production of stackable tray packs in unlimited quantity while their lateral panels are parallel to the utilization.
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A package for a food product such as a cylindrical sandwich includes an elongate central strip having a plurality of fold lines defining a series of panels. A central panel of the series includes a central flap connected at each side edge, and other closure flaps are connected to at least some of the other panels. The panels are folded with respect to each other so that the endmost panels are positioned to define a polygonal cross-section for the package. The closure flaps and central flaps are folded to close the package. An outer portion of each central flap is free from the remaining closure flaps to permit outward folding of the panels for access to the food product. Several alternative embodiments are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for physical therapy and more particularly, to a suspension system for walk training, which is conveniently adjustable to fit different users and different walk training requirements.
2. Description of the Related Art
Various gait training devices are known for physical therapy. Further, a suspension system may be used with a gait training device to help the patient when taking a walk training therapy. A conventional suspension system for this purpose simply uses a suspension mechanism to help the patient stand on the floor. This suspension mechanism is not vertically stretchable to match with the patient's walking motion.
In recent years, suspension systems having a vertically stretchable function have been developed to help patients in walk training. These suspension systems commonly use an elastic rope and a tensile spring to suspend a suspension rod. When in use, the patient is fastened with a harness and then the harness is hung on the suspension rod. However, these improved designs of suspension systems are still not satisfactory in function because they are not adjustable to fit different patients having different body heights or to fit different suspension requirements. Further, these suspension systems are commonly complicated and expensive, not economic to hospitals and patients.
SUMMARY OF THE INVENTION
The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide a suspension system for walk training, which can conveniently be adjusted to change the elevation of the suspension rod to fit different users. It is another object of the present invention to provide a suspension system for walk training, which can conveniently be controlled to adjust the suspension force to fit different training requirements.
To achieve these and other objects of the present invention, the suspension system comprises a framework, the framework comprising two posts vertically arranged in parallel, a top rail horizontally connected between the posts, and two wheel assemblies respectively provided at the posts at a bottom side for moving the framework on a flat surface; a suspension mechanism, the suspension mechanism comprising a suspension rod suspending below the top rail, and a suspension rope mounted in the framework to suspend the suspension rod from the top rail; a spring force control unit fixedly mounted in the framework and connected with one end of the suspension rope for stretching the suspension rope and adjusting the stretch force to the suspension rope; an elevation adjustment unit fixedly mounted in the framework and adapted to move the suspension rope and to further adjust the suspension elevation of the suspension rod; and a suspension force measurement unit, the suspension force measurement unit comprising a pull force sensor connected in series to the suspension rope for measuring the pull force applied to the suspension mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a suspension system according to the present invention.
FIG. 2A is an exploded view in an enlarged scale of a part of the suspension system according to the present invention, showing the structure of the spring force control unit.
FIG. 2B is an assembly view of FIG. 2A .
FIG. 3A is an exploded view in an enlarged scale of a part of the suspension system according to the present invention, showing the structure of the elevation adjustment unit.
FIG. 3B is an assembly view of FIG. 3A .
FIG. 4A is an exploded view in an enlarged scale of a part of the suspension system according to the present invention, showing the structure of the suspension force measurement unit.
FIG. 4B is an assembly view of FIG. 4A .
FIG. 5 is a cutaway view of the suspension system according to the present invention.
FIG. 6 is a schematic drawing showing one application example of the present invention.
FIG. 7 is a schematic drawing showing another application example of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1˜5 , a suspension system for walk training in accordance with the present invention is shown comprised of a framework 10 , a suspension mechanism 20 , a spring force control unit 30 , an elevation adjustment unit 40 , and a suspension force measurement unit 50 .
The framework 10 comprises a top rail 11 , two posts 12 respectively connected to the two distal ends of the top rail 11 to hold the top rail 11 in horizontal, two wheel assemblies 121 respectively fastened to the posts 12 at the bottom side for allowing movement of the framework 10 on the floor conveniently, and two handrails 122 respectively adjustably provided at the posts 12 at a suitable elevation. According to this embodiment, the top rail 11 and the posts 12 are respectively formed of hollow frame bars.
Referring to FIG. 1 again, the suspension mechanism 20 comprises a suspension rod 21 , two hanging hooks 211 respectively provided at the two distal ends of the suspension rod 21 for securing a harness (not shown) to be fastened to the patient who is going to take the walk-training exercise, and a suspension rope 22 , which is inserted through the top rail 11 and has a first end extended out of a bottom center hole (not shown) of the top rail 11 and fixedly fastened to the midpoint of the suspension rod 20 and a second end extending through the elevation adjustment unit 40 in one of the two posts 12 and then extending through the top rail 11 into the inside of the other one of the two posts 12 and coupled to the spring force adjustment unit 30 (further, pulleys are used to guide movement of the suspension rope 22 ).
Referring to FIGS. 1 , 2 A, 2 B and 5 again, the spring force control unit 30 comprises a holder frame 31 fixedly mounted inside one post 12 , a winch 32 pivotally supported on the inside of the holder frame 31 , a torsional spring 33 , which is supported on (a shaft at) one side of the winch 32 and has a first end fixedly connected to one side of the winch 32 and a second end, a worm gear 34 pivotally mounted inside the holder frame 31 and fixedly connected to the second end of the torsional spring 33 , a crank handle 35 pivotally mounted in the respective post 12 , and a worm 351 fixedly provided at one end of the crank handle 35 and meshed with the worm gear 34 . The second end of the aforesaid suspension rope 22 is connected to the winch 32 . The torsional spring 33 imparts a biasing force to the winch 32 , causing the winch 32 to roll up the suspension rope 22 .
Referring to FIGS. 1 , 3 A, 3 B and 5 again, the elevation adjustment unit 40 comprises a holder frame 41 fixedly mounted inside the other post 12 , a vertical screw rod 42 pivotally mounted on the holder frame 41 at the top, a nut 43 threaded onto the vertical screw rod 42 above the holder frame 41 , a pulley 44 fixedly fastened to the nut 43 , a crank handle 45 pivoted to the respective post 12 , and a bevel gear transmission mechanism 421 coupled between the crank handle 45 and the bottom end of the vertical screw rod 42 . Rotating the crank handle 45 clockwise/counter-clockwise will rotate the vertical screw rod 42 , thereby causing the pulley 44 to be moved with the nut 43 upwards/downwards along the vertical screw rod 42 . Further, the aforesaid suspension rope 22 extends over the pulley 44 and connected between the suspension rod 21 and the winch 32 . Therefore, rotating the crank handle 45 can adjust the elevation of the suspension rod 21 .
Referring to FIGS. 4A , 4 B and 5 again, the suspension force measurement unit 50 comprises a pull force sensor 51 , which is mounted inside the top rail 11 and has two ends connected in series to the suspension rope 22 for measuring the suspension force of the suspension mechanism 20 , a track 53 fixedly mounted inside the top rail 11 and extending along the length of the top rail 11 , a slide 52 fixedly provided at the bottom side of the pull force sensor 51 and coupled to and movable along the track 53 , two stop blocks 531 respectively provided at the track 53 near the two ends of the track 53 to limit the moving distance of the slide 52 on the track 53 , and two buffer springs 532 respectively provided at the stop blocks 531 and facing the slide 52 for buffering the striking force of the slide 52 .
The use of the present invention will be outlined hereinafter with reference to FIGS. 6 and 7 and FIG. 1 again. After the harness has been fastened to the patient's body, the hanging hooks 211 of the suspension mechanism 20 are fastened to the harness by means of the help of the therapist or another person. At this time, the patient can stand up and hold the handrails 122 with the hands, and then start to walk (see FIG. 6 ) or to run on a treadmill (see FIG. 7 ).
Referring to FIGS. 2A and 2B again, because the suspension rope 22 has one end coupled to the winch 32 and the torsional spring 33 imparts a biasing force to the winch 32 to roll up the suspension rope 22 , the suspension rod 21 is smoothly moved up and down following the movement of the patient.
Further, the therapist can operate the crank handle 35 to rotate the worm gear 34 , so as to further adjust the spring force of the torsional spring 33 subject to different operation requirements. Further, the engagement between the worm gear 34 and the worm 351 is automatically locked, preventing reverse rotation of the winch 32 . Lock means to automatically lock the engagement between the worm gear 34 and the worm 351 can easily be achieved by means of conventional techniques. Therefore, the therapist can easily adjust the suspension force of the suspension mechanism 20 , controlling the vertical moving range of the suspension rod 21 to fit different walk training requirements for different patients.
Referring to FIGS. 3A , 3 B and 5 again, the therapist can operate the crank handle 45 of the elevation adjustment unit 40 to pull or release the suspension rope 22 and to further adjust the elevation of the nut 43 and the pulley 44 , so as to further adjust the elevation of the suspension rod 21 of the suspension unit 20 . When lowering the elevation of the pulley 44 , the suspension rod 21 is relatively lifted. On the contrary, when lifting the pulley 44 , the suspension rod 21 is relatively lowered.
Referring to FIGS. 4A and 4B again, the pull force sensor 51 of the suspension force measurement unit 50 is connected in series to the suspension rope 22 of the suspension mechanism 20 . During operation of the suspension system, the indicator or display means (not shown) that is electrically connected to the pull force sensor 51 automatically indicates the suspension force of the suspension mechanism 20 . Further, the stop blocks 531 and the buffer springs 532 limit the moving distance of the slide 52 on the track 53 , preventing falling of the patient during walk training.
A prototype of suspension system has been constructed with the features of FIGS. 1˜7 . The suspension system functions smoothly to provide all of the features discussed earlier.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A suspension system for walk training in physical therapy is disclosed to include a framework formed of a top rail and two wheeled posts supporting the top rail, a suspension mechanism, which has a suspension rod suspending from the top rail by a suspension rope for securing a harness for a patient, a spring force control unit fixedly mounted in the framework for stretching the suspension rope and adjusting the stretch force to the suspension rope, an elevation adjustment unit fixedly mounted in the framework for adjusting the elevation of the suspension rod, and a suspension force measurement unit for measuring the pull force of the suspension rope.
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RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
Broadly speaking, this invention relates to altitude sensing means suitable for use with altitude control systems or with pilot warning systems for aircraft. More particularly, in a preferred embodiment, this invention relates to a barometric altimeter combined with a radar altimeter.
A common type of altimeter is the pressure responsive altimeter which includes an aneroid barometer arrangement having expansible bellow means. Other types of altimeters have been developed based upon the principle of radar which utilizes reflected signals from the surface of the earth. These radar altimeters have means for sensing and measuring the absolute altitude above the earth's surface.
A barometric altimeter measures the pressure of atmospheric air which can be used for determining the true altitude above sea level but cannot detect actual height above terrain. In contrast, a radar sensing device accurately measures the actual height above the terrain but cannot provide reliable readings during some flight attitude conditions. For example, it is well recognized that sharp banks, dives and climbing attitudes of an aircraft will cause unreliable altimeter signals from a radar unit due to the aircraft's pitch and roll angles being greater than the radar altimeter's cone of operation. Because of this, radar altimeters generally include an indicator of whether the reading is valid or invalid. Furthermore, a failure in radar signals will cause a radical change in an altitude control system, especially during a low altitude, terrain following flight.
It has been proposed that barometric and radar altitude sensors be combined so that the advantages of both can be utilized while the disadvantages of the individual sensors are neutralized. For example, U.S. Pat. No. 3,140,483 combines barometric and radar altimeters using complex analog devices. While this patent is good for its purpose of generating an altitude error signal for driving an aircraft control surface, it does not provide a true and absolute reading of altitude above ground.
SUMMARY OF THE INVENTION
One of the principal objects of this invention, therefore, is to provide an altitude sensing arrangement which provides an output reading of the absolute altitude above the earth's surface, even during periods when the radar altimeter output is not valid.
A feature of the invention relates to an arrangement incorporating a barometric altitude sensing system with a radar altitude sensing system such that the barometric sensor provides an alternate altitude sensor to update the altitude reading in the event that the radar sensor fails to deliver a valid signal. In this manner, the output continues to indicate the altitude above the earth's surface relative to the surface level at the last valid radar altimeter output.
Another feature of the invention is the provision of an altitude sensing system having in combination a barometric pressure altimeter and a radar altimeter with digital logic to compare a pilot selected altitude with a true altitude above the earth's surface.
Yet another feature of the invention is the provision of an apparatus to trigger an electrical warning signal whenever the true altitude falls below the pilot selected altitude.
DESCRIPTION OF THE DRAWING
The single FIGURE is a functional block diagram of one embodiment of the radar-barometer altimeter circuit according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The drawing illustrates the preferred embodiment of the invention. Radar altitude as a linear DC analog signal and an associated validity sign are provided by a commercial or military radar altimeter 1, for example, a Honeywell type AN/APN-194 or Sunstrand type AVH-5 radar altimeter. If necessary the DC analog voltage may be scaled by a potentiometer 2 in order to make the signal compatible with a connecting analog-to-digital converter 4. Analog-to-digital converter 4 converts the scaled analog altitude signal into a digital representation upon a convert command at time t 1 . At the same time, t 1 , the validity status of the radar altimeter is stored in a D-type flip-flop 6.
A barometric altimeter indicated at 8 may be of the type widely used on aircraft, such as an ARINC 565, which provides a synchronous, 3 wire, AC analog signal. This signal is applied to a corresponding synchronous motor attached to the cockpit altimeter instrument to provide precise meter movement. In the invention, the three synchronous, AC analog signals are connected to a synchro-to-digital (S/D) converter to provide a digital representation of barometric altitude. The S/D converter (a specialized A/D converter) may be of any suitable commercially available design, such as, for example, the Computer Conversion Corp. Model SDC 40. The digital representation is then fed to a memory (A) where it is continually updated.
A clock 12 and a ring counter 14 provide clocking pulses t 1 , t 2 , t 3 , and t 4 on four strobe lines which are pulsed at times separated by the clock period. Typically, a clock frequency would be on the order of 1 KHz which would result in the strobe pulses being separated by 1 millisecond. Although other values may be used, the strobe separation must be sufficient to prevent accepting or changing data prematurely.
When the ring counter 14 initializes time t 2 , a memory (C) stores the digital representation of radar altitude provided by the analog-to-digital converter 4. Memory (A) stores the digital representation provided by the synchro-to-analog converter 10 at the time of t 2 plus a finite delay time imposed by a delay circuit 19. Any delay is acceptable so long as it does not extend to time t 3 . Also at time t 2 , a memory (B), connected in series with memory (A), stores the barometric altitude which was stored in memory (A) during the previous time cycle.
The output of memory (A) through signal line A, together with the inverted output of memory (B) through signal line B, are inputted to an adder 26. The adder 26 is connected to a positive source voltage, V+, and is electrically grounded in such a manner to provide the proper sign bit. As a result, the function of adder 26 becomes subtraction of memory (B) contents from memory (A) contents by making memory (B) contents appear as a negative one (-1's) complement. The output of adder 26 is, therefore, the -1's complement of the barometric altitude change over the time between two t 1 strobes. As will be discussed in greater detail below, the barometric altitude change will be made available for addition to the radar or radar/barometric combined altitude.
The information contained in memory (C) is fed into data selector 24 which passes the information to memory (D) when the trigger signal from the D type flip-flop 6 applied to data selector 24 is "high". A "high" signal is the proper output of the D type flip-flop 6 when the rader altimeter validity signal is "high" (i.e., valid) at time t 1 .
The data from the data selector is stored in memory (D) at time t 3 . The same data is transferred directly to memory (E) at time t 4 . Two memories are utilized to prevent the data being stored by memory (E) from changing when the output of memory (D) changes.
If the radar altimeter validity signal is "low" (i.e., not valid) at time t 1 , the D type flip-flop 6 will not trigger data selector 24 to pass the contents of memory (C) on to memory (D). Instead, the output of adder 26, which represents the barometric altitude change since the last time t 1 , is fed through input signal line F to another adder 28. Information stored in memory (E), which contains the digital representation of radar altitude is fed through signal line E to adder 28 and summed with the output of adder 26. Thus, the resultant output of adder 28 (indicated in the drawing as signal line G) is the barometric altitude change added to the last valid radar altitude. This combined radar/barometric altitude is fed into data selector 24 and is the information stored in memory (D) when the radar altimeter validity signal caused the D type flip-flop 6 to generate a "low" trigger signal to data selector 24. Since memory (E) is directly connected to memory (D), the combined radar/barometric altitude information will be transferred to memory (E) at subsequent time t 4 . As a result, the signals on the output bus of memory (E) could contain either combined radar/barometric altitude data or solely radar altitude data, either of which would be fed into adder 28 for updating during the next time cycle.
Memory (E), which contains the digital representation of radar/barometric altitude data, is directly connected to digital-to-analog converter 42. Digital-to-analog converter 42 converts the digital altitude information into an analog DC output, which is then fed into amplifier 44, where the analog signal is buffered and scaled producing a final output signal. The scaling parameter is determined by the altitude indicator utilized, such as a cockpit altitude indicator or other system such as a ground proximity warning system (GPWS).
The output of memory (E) is also connected to comparator 38, together with a signal from pilot selectable digital switch 36. The pilot, using digital switch 36, selects the altitude which he desires to maintain. Comparator 38 compares the combined altitude stored in memory (E) with the altitude selected by the pilot using digital switch 36. Comparator 38 will output a "high" signal if the selected altitude is higher than the radar and barometric combined altitude. The comparator 38 output signal is connected to a D type flip-flop 40, which is clocked at time t 4 , and delayed by time delay circuit 32. Any delay time may be used so long as it does not extend the time to t 1 . A delay is needed to insure that the data of memory (E) is stabilized. The resulting output of the D type flip-flop 40 will be high and will trigger a cockpit warning signal if the combined radar/barometric altitude is below the pilot selected altitude.
Delay circuits 19 and 32 could be implemented by pairs of inverters, or by one shot multivibrators. Adders 26 and 28 can be implemented by four-bit adders, while the memories could utilize Hex or Quad D flip-flops. The data selector can be implemented by a Quad two-line to one-line data selector.
In summary, the output signal of amplifier 44 is an analog signal of height above terrain, which is solely radar altitude if the radar altimeter signal is valid. When the radar altitude signal becomes invalid, the last valid radar altitude, which is stored in memory (E), is added to the change in barometric altitude since the last valid radar altitude was stored. This combined altitude is then stored in memory (E), and the output signal of amplifier 44 then becomes radar and barometric combined altitude.
Thus, while preferred constructional features of the invention are embodied in the structure illustrated herein, it is to be understood that changes and variations may be made by the skilled in the art without departing from the spirit and scope of the invention.
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An altitude sensing arrangement which combines the advantages of a barometric altimeter with a radar altimeter. The apparatus monitors the radar altimeter's associated radar validity signal and selects the radar altimeter's reading when the validity signal indicates a valid condition. Alternately, when the validity signal does not indicate a valid condition, the invention computes the difference in barometric altitude since the last valid radar altimeter reading and sums this difference with the last valid reading from the radar altimeter to produce a combined altitude reading.
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BACKGROUND OF THE INVENTION
This invention relates to a process and apparatus for continuous single-stage production of a homogeneous solution of cellulose in water-containing amine oxides from cellulose and aqueous amine oxides, preferably N-methylmorpholine N-oxide (NMMO), at temperatures in the range from 50 to 130° C. under reduced pressure by water evaporation.
The dissolving of cellulose in amine oxides having a defined water content and at temperatures above 70° C. is known (DRP 713 486; U.S. Pat. No. 3,447,939). The dissolving proceeds very slowly. The dissolving takes place substantially more rapidly when the cellulose is dispersed in aqueous NMMO and the excess water is subsequently distilled off under reduced pressure while stirring at temperatures above 85° C. to simultaneously dissolve the cellulose (GB 8 216 566).
It is further known to mix comminuted cellulose with water-containing NMMO in an annular layer mixer (WO 96/33221) or a horizontal mixing chamber equipped with rotor and radial stirring elements (WO 94/28217). The homogeneity of the suspension can be improved by high consistency grinding. The suspension is converted into a solution by means of thin film evaporators (EP 356 419) or in the shearing zone of a horizontal screw dissolver (DE 4 441 468).
It is further known to produce cellulose solutions continuously by, in a first stage, the cellulose and aqueous NMMO being dispersed in a horizontal twin-screw kneader and the suspension being metered via an intervessel continuously into a horizontal single-screw kneader and converted into a solution under reduced pressure by water evaporation (A. Diener and G. Raouzeos Chemical Fibers International 49 [1999] 3 p. 40-42; DE 19 837 210).
The processes all have in common that the cellulose solution is fundamentally produced in two spatially separate stages, namely on the one hand in the suspending of the comminuted cellulose in the highly water-containing amine oxide with or without aftertreatment and secondly in the converting of the suspension into the actual solution by shearing and water evaporation.
It is an object of the present invention to provide a process and apparatus for continuous single-stage production of a homogeneous solution of cellulose in water-containing amine oxides. In other words, cellulose and water-containing amine oxide, preferably NMMO, are continuously converted in one stage into a homogeneous cellulose solution in an apparatus without explicit transportation and metering of a suspension and fed to the potential consumer along the shortest possible path.
SUMMARY OF THE INVENTION
The foregoing object is achieved according to the invention by providing a process wherein
(a) water-containing cellulose is fed into the first section of an evacuated first shearing zone of a mixing/kneading reactor, homogenized and heat treated, (b) preheated water-containing amine oxide is fed into the second section of the first shearing zone of the mixing/kneading reactor, mixed with the water-containing cellulose by shearing, homogenized and heated up with the onset of water evaporation, (c) water is removed in the third section of the first shearing zone of the mixing/kneading reactor by kneading, shearing and heat-treating the suspension until complete transformation into a cellulose gel, (d) the cellulose gel is converted in the second shearing zone of the mixing/kneading reactor into a homogeneous solution under reduced pressure by cooling, kneading and shearing, (e) the homogeneous solution is separated by means of temperature-controlled screw conveyors, preferably in a twin-screw embodiment, from the evacuated part of the mixing/kneading reactor, transported and (f) the homogeneous solution is directly fed to the consumer via pumps and safety filters.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail with reference to the following detailed description and drawings wherein:
FIG. 1 schematically illustrates an apparatus in accordance with the present invention;
FIG. 2 is a relaxation spectrum for the cellulose material of Example 1; and
FIG. 3 is a particle size distribution for Example 1.
DETAILED DESCRIPTION
The solution quality is characterized by the particle content determined by means of laser diffraction and the size distribution of the particles as extensively described in the literature (Ch. Michels and F. Meister Das Papier 51 [1997]4 p. 161-165; B. Kosan and Ch. Michels Chemical Fibers International 49[1999]3 p. 50-54). It is convenient to try to express the particle content and the particle distribution in just one parameter, the so-called filter value. The filter value is defined as the ratio of the maximum particle diameter X m to the logarithm of the particle count N 10 in the size class 10 μm.
F p = 10 · X m lgN 10
Solutions having filter values<50 lead to very high spinning consistencies and filter values<100 to high spinning consistencies.
The solution state achieved is described by the zero shear viscosity, the relaxation time and the relaxation time spectrum which are all readily available from rheological data. The methods have likewise been extensively described in the literature (Ch. Michels, Das Papier 52[1998]1 p. 3-8). In an embodiment of the process according to the present invention, the cellulose or cellulose mixture is subjected to an activation. It can be a hydrothermal (DD 298 789) or enzymatic (DE 4 439 149) pretreatment. The activating of the cellulose increases the dissolving rate and improves solution quality.
In a further embodiment of the process according to the invention, a portion of the water-containing NMMO is replaced with diluents, for example ε-aminocaprolactam, piperidone, pyrrolidone or polyvinylpyrrolidone-methacrylate copolymer. The diluent lowers the melting point of the NMMO solvent and thus makes it possible to operate at a lower temperature.
In a further embodiment of the process according to the invention, additives are metered simultaneously with the cellulose or the water-containing amine oxide. The additives, for example cellulose derivatives, starch, starch derivatives, titanium dioxide, silicates, kaolin, carbon black, chitosan, surfactants, polyethyleneimine, etc, can be solid, liquid and/or soluble in the amine oxide. Nonsoluble solid additives are advantageously mixed with the cellulose or metered separately. The stated object is further achieved according to the invention in relation to the apparatus mentioned in the beginning when a twin- or more highly screwed kneading/mixing reactor, having at least two heating/cooling zones and a rotary speed controlled drive unit, is assigned a vacuum station, two or more vacuum-tight metering units, a screw conveyor as discharge unit, a safety filter, two feed pumps and a potential consumer. It is convenient to use as the kneading/mixing reactor a horizontal twin-screw “Co Rotating Processor” (LIST AG Arisdorf Switzerland) having two heating/cooling zones and a freely chooseable screw speed to set the requisite shearing zone. The kneading/mixing screws of the reactor corotate. The first heating/cooling zone is assigned an open-loop control piston pump for metering water-containing cellulose, a heated pump having an adjustable closed-loop control valve for metering the water-containing NMMO and optionally one or more units for metering one or more additives. A vacuum station made up of one or more vacuum pumps and a condensation unit supplies the kneading/mixing reactor with the requisite underpressure to remove the water. A large-volume vertical twin-screw unit disposed at the outlet of the corotating processor separates off the kneading/mixing reactor on the vacuum side, takes over the feeding of the solution and simultaneously serves as a buffer to equalize demand fluctuations of the potential consumer. The twin-screw unit is followed by a safety filter situated between two pumps. The pumps and the safety filter are designed in such a way that a shear gradient of 5[1/s] is not exceeded. The pressure difference between the filter inlet and outlet is measured, recorded and achieves values in undisrupted operation which differ only insignificantly from zero.
In another embodiment of the apparatus according to the present invention, the kneading/mixing reactor used is an opposite rotating processor in which the kneading/mixing screws of the reactor rotate in opposite directions. The invention will be further illustrated with reference to drawings and examples. FIG. 1 shows the apparatus according to the present invention, comprising the kneading/mixing reactor 1 having heating/cooling zones 1 . 1 and 1 . 2 and a drive unit 1 . 3 , the vacuum station 2 , the metering units 3 4 5 , the screw conveyor 6 , the safety filter 7 , the feed pumps 8 9 and the consumer 10 .
EXAMPLE 1
The kneading/mixing reactor used was a “LIST-CRP 63 Batch Co-Rotating Processor” having two heating/cooling zones. 364 g/min of comminuted enzymatically pretreated and stabilized cellulose (cuoxam DP 540; molecular dispersity U η =5.8; water content 49.0%) via an open-loop control piston pump and 1 405 g/min of preheated NMMO (water content 16.0%) at 85° C. via an open-loop control unit (made up of pump and closed-loop control valve) are metered in succession a minimal interval apart into the first shearing zone of the reactor. Pronounced shearing under an applied vacuum of 150 mbar produces intensive mixing and distillative removal of the excess water (about 222 g/min) with simultaneous heating of the suspension to a bulk temperature of 115° C. After passing through the first shearing zone (residence time 15-20 minutes), the mixture appears glassy, highly viscous and is present as a swollen gel. In the second shearing zone of the reactor, under continued shearing and with simultaneous cooling to a bulk temperature of 85° C., the gel is converted into a solution, which is subsequently taken up by the vertical twin-screw conveyor, further homogenized and fed to the precision gear pump. This conveys at a constant bulk temperature of 85° C. 1 334 ml/min of solution through a safety filter having a mesh size of 15 μm to the second pump, which feeds the same amount of solution to the consumer, a fiber spinning pilot plant. The pressure difference in the safety filter was zero even after many hours of operation. The solution had a composition of 12.0% by mass of cellulose, 76.3% by mass of NMMO and 11.7% by mass of water. The zero shear viscosity at 85° C. was 5 360 Pas, the relaxation time λ m at the frequency maximum was 5.4 seconds and the dispersity U η =5.8.
The dispersity U η is obtained from the ratio of the zero shear viscosity η 0 to the “viscosity contribution η” at the crossing point of the dynamically recorded deformation curves [G′; G″=f(ω)], i.e. when the storage modulus G′ and the loss modulus G″ have the same magnitude.
U η = η 0 η ″ - 1
The index η is intended to indicate that the dispersity results from rheological data and not from the determination of the number and mass averages of the molar mass.
The solution has a relaxation time spectrum as depicted in FIG. 2 and a particle distribution (determined by laser diffraction) as depicted in FIG. 3 . The particle content is 4.7 μl/kg of solution, the particle diameter frequency maximum is 6.6 μm, the maximum particle diameter is 16.5 μm and the filter value computed as 28 .
EXAMPLE 2
Example 2 is carried out substantially similarly to Example 1, except that the mixing/kneading reactor used was an approximately equal-sized LIST-ORP Conti opposite rotating processor and the residence time in the reactor was higher by a factor of 1.5. The solution quality and the solution state substantially corresponds to that of the solution in Example 1.
EXAMPLE 3
The kneading/mixing reactor differs from that in Example 1 in that 3 components can be metered separately into the first shearing zone.
The open-loop control piston pump is used to meter 344 g/min of comminuted hydrothermally pretreated and stabilized cellulose having a water content of 46% by mass, comprising a mixture of 95 parts of spruce sulfite pulp (cuoxam DP 490; U η =5.9) and 5 parts of cotton linters pulp (cuoxam DP 1900; U η =3.4) and two separate open-loop control units (made up of pump and closed-loop control valve) are used to meter 1 328 g/min of preheated NMMO (water content 20% by mass) at 90° C. and 119 g/min of polyvinylpyrrolidone (PVP Produkt VP-MA91 W from BASF Ludwigshafen) which simultaneously contained 0.5% by mass of titanium dioxide. Shearing under an applied vacuum of 140 mbar produced intensive mixing, distillative removal of about 260 g/min of water with simultaneous heating of the suspension to 110° C. After the gel state has been attained, the second dissolving operation takes place with simultaneous cooling in the second shearing zone to 75° C. Screw conveyor, safety filter and pumps fed the consumer, a filament spinning machine for coarse denier filament yarns, with 1 530 g/min of spinning solution having a bulk temperature of 75° C. The solution consisted of 12.2% by mass of cellulose, 69.5% by mass of NMMO, 7.7% by mass of PVP and 10.6% by mass of water. The zero shear viscosity at 85° C. was 3 600 Pas, the relaxation time λ m =6.5 seconds and the dispersity U η =5.8. The particle analysis revealed a particle content of 8.7 μl/kg of solution, a particle diameter at the frequency maximum of 10.5 μm and a filter value of 56.
EXAMPLE 4
Example 4 was carried out similarly to Example 3, except that the mixing/kneading reactor used was a single-screw horizontal List Discotherm B-Conti. Instead of the polyvinylpyrrolidone copolymer the same amount of preheated ε-aminocaprolactam are metered in. The residence time has doubled and the solution quality substantially corresponds to the solution in example 3.
EXAMPLE 5
In a mixing/kneading reactor as per Example 3, 272 g/min of comminuted cellulose (cuoxam DP 430, water content 35% by mass, dispersity 6.8) via an open-loop control piston pump, 71 g/min of polyethyleneimine (commercial Polymin from BASF Ludwigshafen, molar mass>750 000, water content 50% by mass) via a precision gear pump and 1 232 g/min of NMMO (water content 23% by mass) via a pump and open-loop control valve are metered, mixed, heated to 120° C. under vacuum of 160 mbar and about 275 g/min of water are distilled off. The bright yellow solution forming in the second shearing zone is at the same time cooled to 80° C., taken over by the screw conveyor and fed via pumps and safety filter to the consumer, a fiber spinning plant, at a rate of 1 300 g/min. The solution consists of 13.6% by mass of cellulose, 2.7% by mass of polyethyleneimine, 73.0% by mass of NMMO and 10.7% by mass of water. The zero shear viscosity at 85° C. is 5 100 Pas, the relaxation time at the frequency maximum is 1.7 seconds, the particle content is 5.2 μl/kg of solution, the particle diameter at the frequency maximum is 9.5 μm and the filter value is 45.
EXAMPLE 6
The kneading/mixing reactor used is a LIST CRP 250 Conti corotating processor having a drive unit for the rotary speed range of 80-120 rpm, 2 heating/cooling zones and 2 metering stubs. 924 g/min of comminuted and enzymatically pretreated cellulose (eucalyptus pulp, cuoxam DP 580, dispersity 5.9, water content 45% by mass) are metered into the first stub and 3 673 g/min of NMMO (water content 45% by mass) into the second stub similarly to Example 1. In the first shearing zone, intensive mixing and kneading under vacuum of 160 mbar is effected with heating of the suspension to 120° C. with simultaneous evaporation of 533 g/min of water until the solution has transformed to the gel state. In the second shearing zone, a homogeneous solution is produced by simultaneous cooling to 82° C. and is taken over by a vertical twin-screw conveyor and fed via two pumps and a safety filter to the consumer at a rate of 3 474 ml/min. The solution consisted of 12.5% by mass of cellulose, 75.9% by mass of NMMO and 11.6% by mass of water, its zero shear viscosity was 6 760 Pas, the relaxation time at the frequency maximum was 6.3 seconds, the particle content was 8.4 μl/kg of solution, and the particle diameter at the frequency maximum was 8.1 μm and the filter value was 32.
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A method and a device for the continuous, single-step production of a homogenous solution of cellulose in hydrous aminoxides on the basis of cellulose and aqueous aminooxides, preferably N-methylmorpholino-N-oxide (NMMO), at temperatures in the range of from 50 to 130° C. under a vacuum and water evaporation. The cellulose and the NMMO are dosed separately to the device, mixed while sheared, the water is evaporated until the mixture is dissolved, the solution is homogenized and directly fed to the consumer via screw conveyors, pumps and filters.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 12/280,832 filed Aug. 27, 2008, which is a National Stage application under 35 U.S.C. §371 of International Application No. PCT/CA2007/000312, filed Feb. 27, 2007, which claims the benefit of U.S. Provisional Patent Application No. 60/777,752, filed Feb. 27, 2006.
FIELD OF THE INVENTION
[0002] This invention relates to a process for improved productivity when undertaking oil recovery from an underground reservoir by the toe-to-heel in situ combustion process employing a horizontal production well, such as disclosed in U.S. Pat. Nos. 5,626,191 and 6,412,557. More particularly, it relates to an in situ combustion process in which a diluent, namely, a hydrocarbon condensate, is injected in the horizontal leg of a vertical-horizontal well pair adapted for use in an in situ combustion process.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF THE PRIOR ART
[0003] U.S. Pat. Nos. 5,626,191 and 6,412,557, incorporated herein in their entirety, disclose in situ combustion processes for producing oil from an underground reservoir ( 100 ) utilizing an injection well ( 102 ) placed relatively high in an oil reservoir ( 100 ) and a production well ( 103 - 106 ) completed relatively low in the reservoir ( 100 ). The production well has a horizontal leg ( 107 ) oriented generally perpendicularly to a generally linear and laterally extending upright combustion front propagated from the injection well ( 102 ). The leg ( 107 ) is positioned in the path of the advancing combustion front. Air, or other oxidizing gas, such as oxygen-enriched air, is injected through wells 102 , which may be vertical wells, horizontal wells or combinations of such wells.
[0004] The process of U.S. Pat. No. 5,626,191 is called “THAI™”, an acronym for “toe-to-heel air injection” and the process of U.S. Pat. No. 6,412,557 is called “Capri™”, the Trademarks being held by Archon Technologies Ltd., a subsidiary of Petrobank Energy and Resources Ltd., Calgary, Alberta, Canada.
[0005] What is needed is one or more methods to increase productivity when undertaking oil recovery from an underground reservoir by the toe-to-heel in situ combustion process employing horizontal production wells.
SUMMARY OF THE INVENTION
[0006] The invention, in a broad embodiment, comprises injecting a diluent in the form of a hydrocarbon condensate via tubing at the toe of the toe-to-heel in situ combustion process employed a horizontal production well, which adds to well productivity and advantageously results in various production economies over the THAI and CAPRI processes to date employed.
[0007] A hydrocarbon condensate is typically a low-density, high-API gravity liquid hydrocarbon phase that generally occurs in association with natural gas. Its presence as a liquid phase depends on temperature and pressure conditions in the reservoir allowing condensation of liquid from vapor.
[0008] The production of condensate from reservoirs can be complicated because of the pressure sensitivity of some condensates. Specifically, during production, there is a risk of the condensate changing from gas to liquid if the reservoir pressure (and thus temperature) drops below the dew point during production. Reservoir pressure (and thus temperature) can be maintained by fluid injection if gas production is preferable to liquid production. Gas produced in association with condensate is called wet gas. The API gravity of condensate is typically 50 degrees to 120 degrees.
[0009] The benefit of injection a high-API hydrocarbon condensate (40+API Gravity) into the tubing in a THAI™ or CAPRI™ in situ hydrocarbon extraction method is that a steam generator or water treatment facilities, as are typically required in THAI™ and CAPRI™ in situ hydrocarbon extraction methods, would not be required. This results in a significant expense savings, not only in avoiding the cost of having to divert a portion of the produced hydrocarbon to produce heated steam, but also in having to have the necessary steam generation equipment and pollution control equipment present to do so. Process operations costs would not be increased since the diluent in liquid form is purchased anyway, and typically in prior art methods involving THAI and CAPRI, mixed with the extracted hydrocarbon at the surface in order to better pump the hydrocarbon to storage facilities or refineries.
[0010] The diluent would dissolve in the liquid oil in the horizontal wellbore and reduce its viscosity, which would advantageously reduce pressure drop in the horizontal well. It would also reduce the density of the oil, facilitating its rise to the surface by gas-lift.
[0011] The addition of a diluent in the form of a hydrocarbon condensate, preferably a liquid, via tubing at the toe of a horizontal production well in a toe-to-heel in situ combustion hydrocarbon recovery process, may be done in combination with any of the steam, water, or oxidizing gas injection methods disclosed in Patent Cooperation Patent Application PCT/CA2005/000883 filed Jun. 6, 2005, and published as WO2005/121504 on Dec. 22, 2005, which is hereby incorporated herein by reference in its entirety.
[0012] Accordingly, in one broad embodiment of the method of the present invention, the invention comprises a process for extracting liquid hydrocarbons from an underground reservoir comprising the steps of:
(a) providing at least one injection well for injecting an oxidizing gas into the underground reservoir; (b) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg; (c) injecting an oxidizing gas through the injection well to conduct in situ combustion, so that combustion gases are produced so as to cause the combustion gases to progressively advance as a front, substantially perpendicular to the horizontal leg, and fluids drain into the horizontal leg; (d) providing a tubing inside the production well for the purpose of injecting a hydrocarbon condensate into said horizontal leg portion of said production well; (e) injecting said hydrocarbon condensate into said tubing so that said condensate is conveyed proximate said toe portion of said horizontal leg portion via said tubing; and (f) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0019] In a further broad embodiment of the invention, the present invention comprises a process for extracting liquid hydrocarbons from an underground reservoir, comprising the steps of:
(a) providing at least one injection well for injecting an oxidizing gas into an upper part of an underground reservoir; (b) providing at least one injection well for injecting a hydrocarbon condensate diluent into a lower part of an underground reservoir; (c) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, wherein the substantially horizontal leg extends toward the injection well, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg; (d) injecting an oxidizing gas through the injection well for in situ combustion, so that combustion gases are produced, wherein the combustion gases progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction of the horizontal leg, and fluids drain into the horizontal leg; (e) injecting a hydrocarbon condensate diluent, into said injection well; and (f) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0026] In a still further embodiment of the invention, the present invention comprises the combination of the above steps of injecting a hydrocarbon diluent to the formation via the injection well, and as well injecting a medium via tubing in the horizontal leg. Accordingly, in this further embodiment, the present invention comprises a method for extracting liquid hydrocarbons from an underground reservoir, comprising the steps of:
a) providing at least one injection well for injecting an oxidizing gas into an upper part of an underground reservoir; b) providing at least one injection well for a hydrocarbon diluent into a lower part of an underground reservoir; c) providing at least one production well having a substantially horizontal leg and a substantially vertical production well connected thereto, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg; d) providing a tubing inside the production well for the purpose of injecting a hydrocarbon condensate diluent into said horizontal leg portion of said production well; e) injecting an oxidizing gas through the injection well for in situ combustion, so that combustion gases are produced, wherein the combustion gases progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction of the horizontal leg, and fluids drain into the horizontal leg; f) injecting a hydrocarbon condensate diluent into said injection well and into said tubing; and (g) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0034] The hydrocarbon condensate contemplated is preferably a condensate selected from the group of condensates consisting of ethane, butanes, pentanes, heptanes, hexanes, octanes, and higher molecular weight hydrocarbons, or mixtures thereof, but may be any other hydrocarbon diluent, such as volatile hydrocarbons such as naphtha or gasoline, or VAPEX (a term of art referring to a hydrocarbon solvent used in a vapour extraction process, such as propane or butane or mixtures thereof).
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a schematic of one embodiment of the in situ combustion process of the present invention with labeling as follows:
Item A represents the top level of a heavy oil or bitumen reservoir, and B represents the bottom level of such reservoir/formation. C represents a vertical well with D showing the general injection point of a oxidizing gas such as air. E represents one general location for the injection of hydrocarbon condensate into the reservoir. This is part of the present invention. F represents a partially perforated horizontal well casing. Fluids enter the casing and are typically conveyed directly to the surface by natural gas lift through another tubing located at the heel of the horizontal well (not shown). G represents a tubing placed inside the horizontal leg. The open end of the tubing may be located near the end of the casing, as represented, or elsewhere. The tubing can be ‘coiled tubing’ that may be easily relocated inside the casing. This is part of the present invention. The elements E and G are part of the present invention and steam or non-oxidizing gas may be injected at E and/or at G. E may be part of a separate well or may be part of the same well used to inject the oxidizing gas. These injection wells may be vertical, slanted or horizontal wells or otherwise and each may serve several horizontal wells. For example, using an array of parallel horizontal leg as described in U.S. Pat. Nos. 5,626,191 and 6,412,557, the steam, water or non-oxidizing gas may be injected at any position between the horizontal legs in the vicinity of the toe of the horizontal legs.
[0042] FIG. 2 is a schematic diagram of the Model reservoir. The schematic is not to scale. Only an “element of symmetry” is shown. The full spacing between horizontal legs is 50 meters but only the half-reservoir needs to be defined in the STARS™ computer software. This saves computing time.
The overall dimensions of the Element of Symmetry are: length A-E is 250 m; width A-F is 25 m; and height F-G is 20 m. The positions of the wells, with reference to FIG. 2 , are as follows: Oxidizing gas injection well J is placed at B in the first grid block 50 meters (A-B) from a corner A. The toe of the horizontal well K is in the first grid block between A and F and is 15 m (B-C) offset along the reservoir length from the injector well J. The heel of the horizontal well K lies at D and is 50 m from the corner of the reservoir, E. The horizontal section of the horizontal well K is 135 m (C-D) in length and is placed 2.5 m above the base of the reservoir (A-E) in the third grid block. The Injector well J is perforated in two (2) locations. The perforations at H are injection points for oxidizing gas, while the perforations at I are injection points for steam or non-oxidizing gas. The horizontal leg (C-D) is perforated 50% and contains tubing open near the toe (not shown, see FIG. 1 ).
[0047] FIG. 3 is a graph plotting oil production rate vs. CO 2 rate of injection in the reservoir, drawing on Example 7 discussed below;
[0048] FIG. 4 is a schematic view of the further embodiment of the process of the present invention, without tubing in the production well, showing the injection of hydrocarbon diluent/condensate low in the reservoir via a lower part of the oxidizing gas injection well;
[0049] FIG. 5 is a schematic view of the further embodiment of the process of the present invention, showing provision of separate injection well, in addition to the oxidizing gas injection well, for injection of a hydrocarbon condensate low in the reservoir; and
[0050] FIG. 6 is a schematic view of the further embodiment of the process of the present invention, showing provision of separate injection well, in addition to the oxidizing gas injection well, for injection of a hydrocarbon condensate low in the reservoir, and showing tubing within the horizontal leg of the production well for additional injection of hydrocarbon diluent/condensate into the horizontal leg.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] The operation of the THAI™ process has been described in U.S. Pat. Nos. 5,626,191 and 6,412,557 and will be briefly reviewed. The oxidizing gas, typically air, oxygen or oxygen-enriched air, is injected into the upper part of the reservoir. Coke that was previously laid down consumes the oxygen so that only oxygen-free gases contact the oil ahead of the coke zone. Combustion gas temperatures of typically 600° C. and as high as 1000° C. are achieved from the high-temperature oxidation of the coke fuel. In the Mobile Oil Zone (MOZ), these hot gases and steam heat the oil to over 400° C., partially cracking the oil, vaporizing some components and greatly reducing the oil viscosity. The heaviest components of the oil, such as asphaltenes, remain on the rock and will constitute the coke fuel later when the burning front arrives at that location. In the MOZ, gases and oil drain downward into the horizontal well, drawn by gravity and by the low-pressure sink of the well. The coke and MOZ zones move laterally from the direction from the toe towards the heel of the horizontal well. The section behind the combustion front is labeled the Burned Region. Ahead of the MOZ is cold oil.
[0052] With the advancement of the combustion front, the Burned Zone of the reservoir is depleted of liquids (oil and water) and is filled with oxidizing gas. The section of the horizontal well opposite this Burned Zone is in jeopardy of receiving oxygen which will combust the oil present inside the well and create extremely high wellbore temperatures that would damage the steel casing and especially the sand screens that are used to permit the entry of fluids but exclude sand. If the sand screens fail, unconsolidated reservoir sand will enter the wellbore and necessitate shutting in the well for cleaning-out and remediation with cement plugs. This operation is very difficult and dangerous since the wellbore can contain explosive levels of oil and oxygen.
[0053] Reference is to be had to the drawings in regard to the invention described in the Summary of the Invention.
[0054] Specifically, in the first broad embodiment of the process of the present invention for extracting liquid hydrocarbons from an underground reservoir set out in the Summary of the Invention and depicted in and with reference to FIG. 1 , such process comprises the steps of:
(a) providing at least one injection well C for injecting an oxidizing gas at location D into the underground reservoir UR; (b) providing at least one production well having a substantially horizontal perforated well casing (horizontal leg) F and a substantially vertical production well connected thereto, the horizontal leg F having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg F; (c) injecting an oxidizing gas through the injection well relatively high in the formation at location D to conduct in situ combustion, so that combustion gases CG are produced so as to cause the combustion gases CG to progressively advance as a front, substantially perpendicular to the horizontal leg F and in the direction of the horizontal leg F, and fluids drain into the horizontal leg; (d) providing a tubing G inside the production well for the purpose of injecting a hydrocarbon condensate into said horizontal leg portion F of said production well; (e) injecting said hydrocarbon condensate into said tubing G so that said condensate is conveyed into said horizontal leg portion F; and (f) recovering hydrocarbons in the horizontal leg F of the production well from said production well.
[0061] In a further embodiment of the process of the present invention for extracting liquid hydrocarbons from an underground reservoir UR comprises injecting such hydrocarbon condensate into an injection well Q separate from the oxidizing gas injection well, as depicted in (and with reference to) FIG. 4 , such process comprises the steps of:
(a) providing at least one injection well C for injecting an oxidizing gas into an upper part (ie at location D) of an underground reservoir UR; (b) utilizing said at least one injection well C for injecting a hydrocarbon condensate diluent into a lower part of an underground reservoir at location E; (c) providing at least one production well having a substantially horizontal leg F and a substantially vertical production well connected thereto, the horizontal leg having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg; (d) injecting an oxidizing gas through the injection well C for in situ combustion, so that combustion gases CG are produced, wherein the combustion gases CG progressively advance as a front, substantially perpendicular to the horizontal leg F and in the direction of the horizontal leg F and fluids drain into the horizontal leg; (e) injecting a hydrocarbon condensate diluent into said injection well Q; and (f) recovering hydrocarbons in the horizontal leg F of the production well from said production well.
[0068] In a further embodiment of the process of the present invention for extracting liquid hydrocarbons from an underground reservoir UR comprises injecting such hydrocarbon condensate into injection well Q, wherein such injection well Q is separate from the oxidizing gas injection well C, as depicted in (and with reference to) FIG. 5 , such process comprising the steps of:
(a) providing at least one injection well C for injecting an oxidizing gas into an upper part of an underground reservoir UR at location D; (b) providing another injection well Q for injecting a hydrocarbon condensate diluent into a lower part of an underground reservoir; (c) providing at least one production well having a substantially horizontal leg F and a substantially vertical production well connected thereto, the horizontal leg F having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg; (d) injecting an oxidizing gas through the injection well C for in situ combustion, so that combustion gases CG are produced, wherein the combustion gases CG progressively advance as a front, substantially perpendicular to the horizontal leg, in the direction of the horizontal leg F, and fluids drain into the horizontal leg; (e) injecting a hydrocarbon condensate diluent into said injection well Q; and (f) recovering hydrocarbons in the horizontal leg of the production well from said production well.
[0075] In a still further embodiment of the invention, the present invention comprises the combination of the above steps of injecting a hydrocarbon diluent to the underground reservoir UR via the separate injection well Q, and as well injecting a medium via tubing G in the horizontal leg F. Accordingly, in this further embodiment, the present invention depicted and as shown in FIG. 6 comprises the steps of:
a) providing at least one injection well C for injecting an oxidizing gas into an upper part of an underground reservoir UR at location D; b) providing at least one other injection well Q for injecting a hydrocarbon diluent into a lower part of an underground reservoir; c) providing at least one production well having a substantially horizontal leg F and a substantially vertical production well connected thereto, wherein the substantially horizontal leg extends toward the injection well, the horizontal leg F having a heel portion in the vicinity of its connection to the vertical production well and a toe portion at the opposite end of the horizontal leg F; d) providing a tubing G inside the production well for the purpose of injecting a hydrocarbon condensate diluent into said horizontal leg F of said production well; e) injecting an oxidizing gas through the injection well C for in situ combustion, so that combustion gases CG are produced, wherein the combustion gases CG progressively advance as a front, substantially perpendicular to the horizontal leg, in a direction of said horizontal leg F, and fluids drain into the horizontal leg F; f) injecting a hydrocarbon condensate diluent into said injection well Q and into said tubing G; and (g) recovering hydrocarbons in the horizontal leg F of the production well from said production well.
[0083] In order to quantify the effect of fluid injection into the horizontal leg F wellbore, a number of computer numerical simulations of the process were conducted. Steam was injected at a variety of rates into the horizontal well by two methods: 1. via tubing placed inside the horizontal well, and 2. via a separate well extending near the base of the reservoir in the vicinity of the toe of the horizontal well. Both of these methods reduced the predilection of oxygen to enter the wellbore but gave surprising and counterintuitive benefits: the oil recovery factor increased and build-up of coke in the wellbore decreased. Consequently, higher oxidizing gas injection rates could be used while maintaining safe operation.
[0084] It was found that both methods of adding steam to the reservoir provided advantages regarding the safety of the THAI™ Process by reducing the tendency of oxygen to enter the horizontal wellbore. It also enabled higher oxidizing gas injection rates into the reservoir, and higher oil recovery.
[0085] Extensive computer simulation of the THAI™ Process was undertaken to evaluate the consequences of reducing the pressure in the horizontal wellbore by injecting steam or non-oxidizing gas. The software was the STARS™ In Situ Combustion Simulator provided by the Computer Modelling Group, Calgary, Alberta, Canada.
[0000]
TABLE 4
List of Model Parameters.
Simulator: STARS ™ 2003.13, Computer Modelling Group Limited
Model dimensions:
Length 250 m, 100 grid blocks, each
Width 25 m, 20 grid blocks
Height 20 m, 20 grid blocks
Grid Block dimensions: 2.5 m × 2.5 m × 1.0 m (LWH).
Horizontal Production Well:
A discrete well with a 135 m horizontal section extending from grid
block 26, 1, 3 to 80, 1, 3
The toe is off set by 15 m from the vertical air injector.
Vertical Injection Well:
Oxidizing gas (air) injection points: 20, 1, 1:4 (upper 4-grid blocks)
Oxidizing gas injection rates: 65,000 m 3 /d, 85,000 m 3 /d or 100,000 m 3 /d
Steam injection points: 20, 1, 19:20 (lower 2-grid blocks)
Rock/fluid Parameters:
Components: water, bitumen, upgrade, methane, CO2, CO/N2, oxygen,
coke
Heterogeneity: Homogenous sand.
Permeability: 6.7 D (h), 3.4 D (v)
Porosity: 33%
Saturations: Bitumen 80%, water 20%, gas Mole fraction 0.114
Bitumen viscosity: 340,000 cP at 10° C.
Bitumen average molecular weight: 550 AMU
Upgrade viscosity: 664 cP at 10° C.
Upgrade average molecular weight: 330 AMU
Physical Conditions:
Reservoir temperature: 20° C.
Native reservoir pressure: 2600 kPa.
Bottomhole pressure: 4000 kPa.
Reactions:
1. 1.0 Bitumen → 0.42 Upgrade + 1.3375 CH4 + Coke
2. 1.0 Bitumen + 16 O2{circumflex over ( )}0.05 → 12.5 water + 5.0 CH4 + 9.5 CO2 +
CO/N2 + 15 Coke
3. 1.0 Coke + 1.225 O2 → 0.5 water + 0.95 CO2 + 0.05 CO/N2
EXAMPLES
Example 1
[0086] Table 1a shows the simulation results for an air injection rate of 65,000 m 3 /day (standard temperature and pressure) into a vertical injector (E in FIG. 1 ). The case of zero steam injected at the base of the reservoir at point I in well J is not part of the present invention. At 65,000 m 3 /day air rate, there is no oxygen entry into the horizontal wellbore even with no steam injection and the maximum wellbore temperature never exceeds the target of 425° C.
[0087] However, as may be seen from the data below, injection of low levels of steam at levels of 5 and 10 m 3 /day (water equivalent) at a point low in the reservoir (E in FIG. 1 ) provides substantial benefits in higher oil recovery factors, contrary to intuitive expectations. Where the injected medium is steam, the data below provides the volume of the water equivalent of such steam, as it is difficult to otherwise determine the volume of steam supplied as such depends on the pressure at the formation to which the steam is subjected to. Of course, when water is injected into the formation and subsequently becomes steam during its travel to the formation, the amount of steam generated is simply the water equivalent given below, which typically is in the order of about 1000× (depending on the pressure) of the volume of the water supplied.
[0000]
TABLE 1a
AIR RATE 65,000 m 3 /day—Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
410
90
0
35.1
28.3
5
407
79
0
38.0
29.0
10
380
76
0
43.1
29.8
*Not part of the present invention.
Example 2
[0088] Table 1b shows the results of injecting steam into the horizontal well via the internal tubing, G, in the vicinity of the toe while simultaneously injecting air at 65,000 m 3 /day (standard temperature and pressure) into the upper part of the reservoir. The maximum wellbore temperature is reduced in relative proportion to the amount of steam injected and the oil recovery factor is increased relative to the base case of zero steam. Additionally, the maximum volume percent of coke deposited in the wellbore decreases with increasing amounts of injected steam. This is beneficial since pressure drop in the wellbore will be lower and fluids will flow more easily for the same pressure drop in comparison to wells without steam injection at the toe of the horizontal well.
[0000]
TABLE 1b
AIR RATE 65,000 m 3 /day—Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Meximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
410
90
0
35.1
28.6
5
366
80
0
43.4
30.0
10
360
45
0
43.4
29.8
*Not part of the present invention.
Example 3
[0089] In this example, the air injection rate was increased to 85,000 m 3 /day (standard temperature and pressure) and resulted in oxygen breakthrough as shown in Table 2a. An 8.8% oxygen concentration was indicated in the wellbore for the base case of zero steam injection. Maximum wellbore temperature reached 1074° C. and coke was deposited decreasing wellbore permeability by 97%. Operating with the simultaneous injection of 12 m 3 /day (water equivalent) of steam at the base of the reservoir via vertical injection well C (see FIG. 1 ) provided an excellent result of zero oxygen breakthrough, acceptable coke and good oil recovery.
[0000]
TABLE 2a
AIR RATE 85,000 m 3 /day—Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /d
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
1074
97
8.8
5
518
80
0
12
414
43
0
36.1
33.4
*Not part of the present invention.
Example 4
[0090] Table 2b shows the combustion performance with 85,000 m 3 /day air (standard temperature and pressure) and simultaneous injection of steam into the wellbore via an internal tubing G (see FIG. 1 ). Again 10 m 3 /day (water equivalent) of steam was needed to prevent oxygen breakthrough and an acceptable maximum wellbore temperature.
[0000]
TABLE 2b
AIR RATE 85,000 m 3 /d. Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /d
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
1074
100
8.8
5
500
96
1.8
10
407
45
0
37.3
33.2
*Not part of the present invention.
Example 5
[0091] In order to further test the effects of high air injection rates, several runs were conducted with 100,000 m 3 /day air injection. Results in Table 3a indicate that with simultaneous steam injection at the base of the reservoir (i.e., at location B-E in vertical well C—ref. FIG. 1 ), 20 m 3 /day (water equivalent) of steam was required to stop oxygen breakthrough into the horizontal leg, in contrast to only 10 m 3 /day steam (water equivalent) at an air injection rate of 85,000 m 3 /day.
[0000]
TABLE 3a
AIR RATE 100,000 m 3 /day—Steam injected at reservoir base.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
1398
100
10.4
5
1151
100
7.2
10
1071
100
6.0
20
425
78
0
34.5
35.6
*Not part of the present invention.
Example 6
[0092] Table 3b shows the consequence of injecting steam into the well tubing G (ref. FIG. 1 ) while injecting 100,000 m 3 /day air into the reservoir. Identically with steam injection at the reservoir base, a steam rate of 20 m 3 /day (water equivalent) was required in order to prevent oxygen entry into the horizontal leg.
[0000]
TABLE 3b
AIR RATE 100,000 m 3 /d. Steam injected in well tubing.
Steam
Injection Rate
Maximum well
Maximum coke
Maximum Oxygen
Bitumen recovery
Average oil
m 3 /day
Temperature,
in wellbore
in wellbore
Factor
Production Rate
(water equivalent)
° C.
%
%
% OOIP
m 3 /day
*0
1398
100
10.4
5
997
100
6.0
0
745
100
3.8
20
425
38
0
33.9
35.6
Example 7
[0093] Table 4 below shows comparisons between injecting oxygen and a combination of non-oxidizing gases, namely nitrogen and carbon dioxide, into a single vertical injection well in combination with a horizontal production well in the THAI™ process via which the oil is produced, as obtained by the STARS™ In Situ Combustion Simulator software provided by the Computer Modelling Group, Calgary, Alberta, Canada. The computer model used for this example was identical to that employed for the above six examples, with the exception that the modeled reservoir was 100 meters wide and 500 meters long. Steam was added at a rate of 10 m 3 /day via the tubing in the horizontal section of the production well for all runs.
[0000]
TABLE 4
Total
Produced
Oil
Cumula-
Mol %
Mol %
Injection
Production Rate,
Gas
Rate
tive Oil
Test
Injection Rate, km 3 /day
Oxygen
CO2
Rate,
km 3 /day
Mol %
m 3 /day
Recovery
#
O2
CO2
N2
Injected
Injected
km 3 /day
CO2
N2
CO2
(1-year)
m 3
1
17.85
0
67.15
21
0
85
13.1
67.2
16.3
41
9700
2
8.93
33.57
0
21
79
42.5
37.9
0.0
96.0
54
12780
3
25
0
0
100
0
25
21.3
0.0
96.0
47
10078
4
17.85
67.15
0
21
79
85
75.0
0.0
96.0
136
20000
5
42.5
0
0
100
0
42.5
38.1
0.0
96.0
57
12704
6
42.5
42.5
0
50
50
85
74.2
0.0
96.0
113
28104
7
8.93
42.5
33.57
11
50
85
47.2
33.6
57.4
70
12000
[0094] As may be seen from above Table 4 comparing Run #1 and Run #2, when the oxygen and inert gas are reduced by 50% as in Run #2, the oil recovery is nevertheless the same as in Run 1, providing that the inert gas is CO2. This means that the gas compression costs are cut in half in Run #2, while oil is produced faster.
[0095] As may further be seen from above Table 4, Run #1 having 17.85 molar % of oxygen and 67.15% nitrogen injected into the injection well, estimated oil recovery rate was 41 m 3 /day. In comparison, using a similar 17.85 molar % oxygen injection with 67.15 molar % carbon dioxide as used in Run #4, a 3.3 times increase in oil production (136 m 3 /day) is estimated as being achieved.
[0096] As may be further seen from Table 4 above, when equal amounts of oxygen and CO2 are injected as in Run #6, still with a total injected volume of 85,000 m 3 /day, oil recovery was increased 2.7-fold.
[0097] Run #7 shows the benefit of adding CO 2 to air as the injectant gas. Compared with Run #1, oil recovery was increased 1.7-fold without increasing compression costs. The benefit of this option is that oxygen separation equipment is not needed.
[0098] Referring now to FIG. 3 , which is a graph showing a plot of oil production rate versus CO 2 rate in the produced gas (drawing on Example 7 above), there is a strong correlation between these parameters for in situ combustion processes. CO 2 production rate depends upon two CO 2 sources: the injected CO 2 and the CO 2 produced in the reservoir from coke combustion, so there is a strong synergy between CO 2 flooding and in situ combustion even in reservoirs with immobile oils, which is the present case.
SUMMARY
[0099] For a fixed amount of steam injection, the average daily oil recovery rate increased with air injection rate. This is not unexpected, since the volume of the sweeping fluid is increased. However, it is surprising that the total oil recovered decreases as air rate is increased. This is during the life of the air injection period (time for the combustion front to reach the heel of the horizontal well). Moreover, with carbon dioxide injected in the vertical well, and/or in the horizontal production well, production rates improved production rates can be expected.
[0100] Although the disclosure described and illustrates preferred embodiments of the invention, it is to be understood that the invention is not limited to these particular embodiments. Many variations and modifications will now occur to those skilled in the art. For definition of the invention, reference is to be made to the appended claims.
[0101] The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
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A modified process for recovering oil from an underground reservoir using the an in situ combustion process. A diluent, namely a hydrocarbon condensate, is injected within a separate wellbore, or alternatively within said separate wellbore and via tubing in a horizontal wellbore portion, preferably proximate the toe, of a vertical-horizontal well pair, to increase mobility of oil.
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BACKGROUND OF THE INVENTION
Present invention relates to a new type of building brick. More particularly, the present invention relates to a new type of building brick which does not require mortar in the construction of buildings.
Until the present invention, the construction of a brick building required the skills of a mason. In addition, labor had to be provided on the job site in connection with the preparation and handling of mortar.
The present invention enables the rapid construction of a building without the mixing of mortar. Furthermore, the construction of a building in accordance with the present invention does not require the skills of a mason.
SUMMARY OF THE INVENTION
An advantage of the present invention is that mortar is not required in the construction of buildings.
Another advantage of the present invention is that it eliminates the need for a skilled mason in the construction of a brick building.
Briefly, in accordance with the present invention, a building brick used for constructing buildings is provided. The brick is provided with two projecting locking members on a first surface and two locking indentations on a second surface opposite the first surface. The projecting locking members on a brick in a first tier of bricks are adapted to fit into the indentations of one or more bricks in an adjacent tier of bricks in order to prevent lateral motion. Magnetic means may be used for applying forces in order to attract bricks in adjacent tiers together.
In another embodiment of the present invention, the bricks may be comprised of partially dried clay and straw. The bricks are then held together by applying layers of water to the surfaces of the bricks to be bonded together. The bricks are laid in position for construction and heat is then applied to form a bond between the bricks intended to be bonded together.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there are shown in the drawings forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a view in perspective of a portion of a building being constructed with bricks in accordance with the present invention.
FIG. 2 is a view in perspective of a brick in accordance with the present invention.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2 in accordance with the present invention.
FIG. 4 is a cross-sectional view of another embodiment of the present invention using magnetic bonding forces.
FIG. 5 is a cross-sectional view of a brick using magnetic bonding forces in accordance with another embodiment of the present invention.
FIG. 6 is a cross-sectional view of a brick in accordance with another embodiment of the present invention.
FIG. 7 is a side-elevation view of a special purpose brick in accordance with the present invention.
FIG. 8 is a view in perspective of still another embodiment of the present invention.
FIG. 9 is a cross-sectional view of a construction of a plurality of bricks of FIG. 8 taken along line 9--9 of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, there is shown in FIG. 1 partially constructed walls 10 and 11 comprised of building brick in accordance with the present invention. The walls are constructed by laying a first tier of bricks 12 on a suitable foundation 13 comprised of a suitable substance, such as concrete. A second tier of bricks 14 is laid on the first tier and positioned so that the center of bricks 14 overlay the joints of bricks 12. Similar tiers of bricks 15 and 16 are consecutively laid to form a wall.
Referring now to FIGS. 1, 2 and 3 taken together, the structure of the building brick is shown in greater detail. Each building brick 16 is provided with two projecting locking members 18 on one of the surfaces as shown in FIGS. 1, 2 and 3. As may be seen from FIG. 3, each brick 16 is provided with a pair of locking indentations 17 on a surface opposite the surface of the projecting locking members. The locking indentations 17 are provided on surface 19 directly opposite the projecting locking members 18 of surface 20. In constructing walls from the building bricks, the projecting locking members 18 fit into the locking indentations 17 of the next tier of bricks. For example, referring to FIG. 1, the projecting locking members of the bricks in tier 15 fit into the locking indentations 17 of building bricks 16 of the top tier. This locking arrangement of projecting members and indentations prevents lateral movement of the bricks.
The building bricks may be held together by means of magnetic forces or by bonding the bricks together as will be described hereinafter. Referring now to FIGS. 2 and 3, there are shown strips 21 and 22 of magnetic material embedded in the brick around the periphery of the projecting locking members 18 and the locking indentations 17. At least one of the pair of strip materials 21 and 22 are permanent magnets. Both pairs of strip materials 21 and 22 may be permanent magnets. However, if only one pair of strip materials 21 and 22 are permanent magnets, the other pair of strips 21 or 22 may be a suitable magnetic material such as iron or permalloy. As long as one of the pairs of strip materials 21 and 22 are permanent magnets, magnetic forces will be set up attracting the magnetic strip material of bricks in an adjacent tier. For example, using the numerical designations of FIG. 1, if the magnetic strip materials 21 surrounding the projecting members 18 on the bricks of tier 14 are permanent magnets, the strip materials 22 of the bricks of tier 15 surrounding the indentations on the bottom of the bricks may be a suitable magnetic material such as soft iron. Alternatively, all strip materials may be permanent magnets.
Referring now to FIG. 4, there is shown a brick 23 in cross section representing another embodiment of the present invention. Brick 23 and the bricks shown in FIGS. 2, 3, 7, 8 and 9 may be constructed of conventional brick compositions such as clay which has been dried or fired. Brick 23 is provided with strips 24 and 25 comprised of a magnetic material. Strips 24 or strips 25 are comprised of permanent magnets. However, if desired, both strips 24 and 25 may be permanent magnets. As long as one of the strips 24 or 25 are comprised of permanent magnets, the other may be comprised of a magnetic material. When the bricks are put together in adjacent tiers, a permanent magnet will be adjacent a piece of magnetic material thereby creating attractive magnetic forces holding bricks in adjacent tiers together. Strips 24 are mounted in the outermost surface of projecting locking members 27 and magnetic strips 25 are mounted in the innermost surface of locking indentations 28.
Referring now to FIG. 5, there is shown a brick 29 illustrating another embodiment of the present invention. Magnetic particles 30 are placed in at least a portion of brick 29 during the brick manufacturing process. preferably, magnetic particles would be deposited in brick 29 in and around projecting members 31 as shown at 30 and around indentations 32 as shown at 33. However, it is understood that magnetic particles could be distributed uniformly throughout brick 29. However, in order to produce the most economical manufacture of the brick, the magnetic particle distribution could be limited to specified areas such as around the projecting members 31 and indentations 32. The magnetic particles as shown in the cross-sectional representation of brick 29 may be permanent magnet particles or, for example, only the upper particle distributions 30 may be permanent magnets and the lower particle distributions 33 may be soft iron or permalloy particles or vica versa.
Referring now to FIG. 6, there is shown another embodiment of the present invention illustrated by a cross-sectional view of a brick 34. Brick 34 is provided with projecting locking members 35 and indentations 36. In constructing a building or a wall with the bricks shown in FIG. 6, magnetic binding forces are not used to hold bricks in adjacent tiers together. Brick 34 is comprised of clay and straw in a partially dried state. The bricks are put together to form a structure as illustrated in FIG. 1. In putting the bricks together to form the structure of FIG. 1, a layer of water is applied to surfaces 37 and 38. Once the bricks 34 are assembled in this manner, heat is applied to fully dry the bricks and form a bond between the bricks by drying the water which was applied to surfaces 37 and 38. The heat may be applied by a radiation lamp. In this manner, the bricks in adjacent tiers are bonded together without the need of magnetic binding forces.
Referring now to FIG. 7, there is shown a special purpose type of brick 39 which may be used in archways and similar other applications. Brick 39 is provided wth a projecting member 40 and a corresponding locking indentation 41. Magnetic strips 42 and 43 are also provided. At least one of the magnetic strips 42 and 43 must be a permanent magnet as described above.
Referring now to FIG. 8, there is shown another embodiment of the present invention comprised of a brick 45 with a pair of triangular projecting locking members 46 and 47. Brick 45 is provided with threaded openings 48 and 49. The threaded openings are provided with threaded cylinders or plugs 50 and 51 which are comprised of a magnetic material.
FIG. 9 illustrates a cross-sectional view of brick 45 in conjunction with cross-sectional views of mating bricks 52 and 53. Brick 45 is also provided with triangular indentations 54 and 55 in a surface opposite the surface carrying projecting members 46 and 47. The lower surface 56 is also provided with threaded cylinders or plugs 57 and 58 of magnetic material. The cylinders or plugs are provided with screwdriver slots as shown at 59 and 60.
The triangular projecting members 46 and 47 in conjunction with mating indentations of bricks in adjacent tiers as shown in FIG. 9 prevent lateral movement of the bricks. The plugs in the upper or lower surface are permanent magnets. Alternatively, the plugs in both the upper and lower surfaces may be permanent magnets. The plugs 50 and 51 of magnetic material set up attractive forces with plugs 61 and 62, respectively, of bricks 52 and 53, respectively.
In view of the above, the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification as indicating the scope of the invention.
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A new building brick for use in the construction of buildings is disclosed. The brick is provided with projecting members and indentations on opposite surfaces. The projecting members and indentations provide resistance to lateral movement of the bricks. The bricks are held together in adjacent tiers by means of magnetic forces. The magnetic materials are located around the periphery of the projecting members and indentations or on the tops of the projecting members and the innermost portion of the indentation. In another embodiment, the bricks may be partially cured and held together by means of applying water to the surfaces to be joined and applying heat.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 61/277,864, filed Sep. 30, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to mounting devices for attaching various accessories to a support structure. More specifically, the present invention relates to mount adapter devices utilizing a spring-loaded push system for quickly and securely attaching firearm accessories to weapon accessory rails.
[0004] 2. Description of the Prior Art
[0005] Universal weapon accessory rails such as the “Picatinny rail” (i.e., MIL-STD-1913 rail) provide a standardized platform for mounting and dismounting firearm accessories to weapons. Generally, accessories including optics, tactical lights, grenade launchers, night vision devices, and other weapon-mounted accessories are not designed for direct attachment to the rails. Thus, mount adapter devices are typically employed to attach accessories to firearms.
[0006] As depicted in FIG. 2 , conventional weapon accessory rails are defined by a grooved mounting feature that serves as the platform used to mount accessories. The grooved mounting feature comprises a plurality of mounting projections 50 extending perpendicular along a longitudinal axis 53 of each rail 43 . The mounting projections 50 are separated by a plurality of transverse grooves 40 evenly spaced along the longitudinal axis 53 of the rail 43 . Each of the mounting projections 50 includes an upper mounting surface 39 and opposite transverse edges 48 and 49 which are beveled to form a first 41 a and a second 41 b inclined proximal surface on opposite sides of the upper mounting surface 39 , a first inclined distal surface 42 a adjacent the first inclined proximal surface 41 a , and a second inclined distal surface 42 b adjacent the second inclined proximal surface 41 b . These mounting projections 50 are provided so that accessories may be mounted to weapon accessory rails using mount adapter devices which are able to grip the edges 48 and 49 of the rails.
[0007] Various mount adapter devices have been suggested for attaching weapon accessories to firearms. A common objective of all mount adapter devices is to releasably and securely fasten an accessory to a weapon. To accomplish this objective prior art devices commonly employ bolts, thumbscrews, or levers to draw together opposing clamping members having inclined surfaces aligned with and facing the inclined surfaces of the mounting projections on the rail. The bolt, thumbscrew, or lever urges a moving clamping member toward the direction of a stationary clamping member. In this manner, the opposing clamping members grip the inclined surfaces of the mounting projections in an effort to attach the device to the rail. Design problems in prior art devices, however, present several disadvantages—one significant disadvantage being insufficient clamping forces.
[0008] Most users of mount adapter devices, especially military or law enforcement personnel, demand the ability to quickly switch from one accessory to another, as well as the ability to easily and quickly mount and dismount the accessory. Particularly in combat settings, efficient field modification of weapon configurations is vital. Yet, current devices are unable to fulfill such user demands.
[0009] Compact and lightweight devices are needed for quickly modifying weapon configurations, but compared to the disclosed invention, prior art devices are large and cumbersome. This design flaw makes tasks such as mounting, dismounting, and switching accessories difficult and time-consuming. Additionally, the comparatively larger prior art devices are more susceptible to being inadvertently forced out of position on the rail by an external force or upon an accidental impact.
[0010] A common type of prior art mount adapter device employs levers or similar actuating members as a means of clamping or locking the device to the rail. Such devices require two hands and too much time to attach the device to the rail. One hand positions and holds the device to the rail while the other hand forces the lever to a lock position. This method of attachment does not provide an efficient means of modifying weapon configurations.
[0011] Furthermore, a fundamental defect encountered with devices employing levers is that the levers are prone to breakage. For example, due to dimensional variations among different rails, if a particular rail happens to be larger than other conventional rails, a user may have to press harder on a lever in order to get the clamping mechanism to properly attach to the rail. The force exerted on the lever can oftentimes cause the lever to break.
[0012] An additional problem of devices employing levers occurs when excessive vibration, recoil, or accidental contact of the lever with an external impact forces the lever to slide to an unlock or release position causing the device and the accessory to detach from the rail. In the case of accessories such as optical sights, a mere one-thousandth of an inch variance in the remounted position causes a one inch shift in the point of aim at one hundred yards. Accordingly, in addition to requiring the user to remount the optical sight, the user would also have to resight (or re-zero) the sight which is inefficient and inconvenient.
[0013] Other prior art devices utilize bolts or thumb screws as opposed to levers. Generally, these devices have one or more knobs that the user must rotate through several 360 degree turns in order to attach or detach the device to the rail. Devices of this type cannot be attached to or detached from the rail as quickly as is sometimes required by users.
[0014] In regards to accessories such as optical sights, it is imperative for accuracy that the optical sight remains rigidly attached to the firearm. Devices that utilize bolts or thumb screws as a locking means, however, are generally manually bolted down. As a result, the device easily comes loose from the rail as the manually tightened bolts do not remain consistently and tightly fastened in place. Additionally, the bolts and thumbscrews protrude out laterally from the mount adapter device when the device is attached to a rail. This makes the bolts and thumbscrews susceptible to catching or snagging on clothing or other external items which can jerk the device and the accessory out of position.
[0015] Another common feature shared by many current devices relies on an opposing cam member to bear against one edge of the rail to attach the device to the rail. Generally, the length of the opposing cam member is substantially less than the length of a main clamping member. For example, in one design currently used, the opposing cam member measures approximately one half of an inch in length while the main clamping member measures approximately three inches in length. This feature results in insufficient holding strength of the device to the rail and leaves the accessory susceptible to misalignment caused by accidental impact, intense recoil, or jarring or dropping the firearm on which the accessory is mounted. Once again this can force the user to waste a great amount of time correcting the positioning, remounting, or resighting the accessory.
[0016] Another problem with devices utilizing a cam member occurs as the cam member moves into a clamping position on the rail. The cam member rubs along and abrades an edge of the rail each time the device is attached to or detached from the rail. This disfigures and wears down the edges of the rails which reduces the ability of such devices to consistently, tightly, and securely attach to the damaged edges. Furthermore, devices utilizing cam members are not designed to account for the dimensional variations seen among different rails. This results in such devices either attaching too tightly to rails and disfiguring the rails as described above, or attaching to loosely to rails and leaving the attached accessory susceptible to misalignment or detachment.
[0017] A mount adapter device is needed that is compact, lightweight, and that provides maximum and consistent clamping forces to attach the device to a rail, thereby allowing the device to withstand the impact of external forces. At the same time the device needs to be sturdy enough to withstand breakage of any parts. Moreover, a device is needed that will securely lock to all rails, including worn or damaged rails, without disfiguring the rails or requiring realignment. Opposed to prior art devices that require tools or two hands to attach the devices to a rail, a device is needed that can be quickly and effortlessly locked to a rail without the necessity of tools and requiring only one hand A device is needed that will retain its precise original orientation and alignment when detached and reattached to a rail, thereby allowing an optical, sighting, or other aiming or targeting device to maintain its zero position when detached and then subsequently reattached to the rail.
[0018] In view of the foregoing, it is apparent that there exists a need in the art for a mount adapter device which overcomes, mitigates, or solves the above problems in the art. It is a purpose of this invention to fulfill this and other needs in the art which will become more apparent to the skilled artisan once given the following disclosure.
OBJECTS AND SUMMARY OF THE INVENTION
[0019] It is an object of the present invention to overcome the above described drawbacks associated with prior art mount adapter devices. To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described, the invention provides for a mount adapter device utilizing a spring-loaded push system that employs a dual locking mechanism to releasably, consistently, and securely lock accessories to a universal weapon accessory rail.
[0020] The mount adapter device of the present invention generally comprises a base including a first base member and a second base member, said first base member being linearly slidable into engagement with the second base member in a first direction, said second base member being linearly slidable into engagement with the first base member in a second direction which is opposite said first direction; said first base member including a first clamping member for engaging a first edge of the rail; said second base member including a second clamping member for engaging a second edge of the rail; a push rod member slidably connecting said first base member to said second base member, said push rod member including a shaft and a knob, said shaft including a first end and a second end, and said knob attached to said first end of the shaft; and a resilient member being received around said push rod member, said resilient member providing a spring force and arranged to force the first clamping member to move in said first direction into locking engagement with the first edge of the rail while simultaneously forcing the second clamping member to move in said second direction into locking engagement with the second edge of the rail.
[0021] In operation, the first base member is connected to the push rod member in a manner that allows the first base member to slide up and down the shaft between the knob and the second base member. The second base member is threadedly fastened to the second end of the push rod member so that the second base member remains attached to the second end of the push rod member at all times. The resilient member provides a spring force which urges the first base member in a first direction down the shaft of the push rod member toward engagement with the second base member and which yieldably opposes movement of the first base member up the shaft toward the knob. At the same time, the resilient member bears against the knob which urges the push rod member in a second direction, opposite the first direction. The second end of the push rod member is attached to the second base member so that the spring force simultaneously urges the second base member in the second direction along with the push rod member.
[0022] In this manner, the resilient member in association with the push rod member creates two directly opposing and moving forces urging the first base member in the first direction and the second base member in the second direction thereby forcing the first and second base members into engagement with one another. This forces the opposing clamping members of the first and second base members into locking engagement with the opposite transverse edges of the rail. Rather than employ a single moving force coming from one direction, as is seen in the prior art devices, the present invention locks to the rail by employing two directly opposing moving forces coming from two opposite directions. This results in two opposing forces, which are approximately equal in magnitude, being applied to the two opposite transverse edges of the rail.
[0023] This spring-loaded push system feature provides numerous advantages over prior art devices. Most notably, rather than employing a moving force coming from one direction, the present device employs two directly opposing moving forces coming from two opposite directions which provides the device with maximum attachment and holding strength that is unparalleled in the art.
[0024] Another advantage provided by the spring-loaded push rod system is that it allows the device to be quickly locked to or unlocked from a rail using only one hand and without the necessity of tools. Moreover, the spring-loaded push system allows the device to self-adjust to compensate for variations in rail dimensions thereby providing a secure and consistent attachment to any rail, including a worn or disfigured rail, as well as providing a locking means that does not damage the rail. Additionally, the spring-loaded push system provides for a uniform tension on all rails regardless of the strength of the user who attaches the device to the rail.
[0025] A further advantage resides in the ability of the device to maintain at least three points of contact with a plurality of mounting projections at all times, whether or not the rail is worn or disfigured. The opposing clamping members facing the first and second inclined proximal surfaces of the mounting projections do not contact said first and second inclined proximal surfaces which allows the device to fit any rail, including rails with damaged edges. The three points of contact are provided by a lower mounting surface of the first base member, which bears against the upper mounting surfaces of the mounting projections, and the opposing clamping members of the first and second base members, which engage the first and second inclined distal surfaces of the mounting projections. This three-point contact provided for by the device, in combination with the two opposing moving forces provided by the spring-loaded push system, provides maximum holding strength which is unparalleled in this field. Experimental tests have demonstrated that the mount adapter device of the present invention can lift at least 1,600 pounds while mounted to a conventional weapon accessory rail without damaging the rail.
[0026] Another advantage of the presently disclosed device resides in the ability of the device to maintain additional points of contact with one or more elected transverse grooves at all times. This advantage is provided by the central portion of the shaft of the push rod member and may be provided by one or more locating members. The central portion of the shaft and the locating members are configured to engage elected transverse grooves between the mounting projections on the rail to prevent forward and backward movement of the device along the longitudinal axis of the rail. The combination of the three-point contact with the mounting projections and the additional points of contact maintained between the push rod member and the locating members with the transverse grooves provides additional holding strength, the ability to withstand intense recoil and external impacts, and the ability to retain the precise original orientation and alignment of the accessory on the firearm upon detachment and reattachment of the device. In this manner, precisely aligned accessories such as sighting, aiming, or targeting devices may be detached from and reattached to the rail without the need for resighting the device.
[0027] Another object of the present invention is to provide a lightweight and compact device that offers no point of entanglement for military or law enforcement personnel's equipment. Still another object is to provide a device that has no loose components that would render the device inoperable should one be inadvertently lost.
[0028] These, together with other objects of the invention, along with various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto 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 a preferred embodiment of the invention.
[0029] Though the present invention is discussed herein particularly with its application to mount adapter devices for firearms, note that it is not intended to limit the spirit and scope of the present invention solely to use in conjunction with firearms. The present invention clearly has a wide range of application in circumstances where a device is intended to be releasably attached in a secure manner to a support structure. Many other uses of the present invention will become obvious to one skilled in the art upon acquiring a thorough understanding of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate a preferred embodiment of the present invention, and together with the description, serve to explain the principles of the invention. It is to be expressly understood that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. In the drawings:
[0031] FIGS. 1A and 1B illustrate exploded isometric views of one example of a mount adapter device constructed in accordance with the teachings of the present disclosure.
[0032] FIG. 2 is an isometric view illustrating the device shown in FIGS. 1A and 1B aligned over a weapon accessory rail.
[0033] FIG. 3 is an end elevational view of the device shown in FIGS. 1A and 1B mounted to the rail shown in FIG. 2 .
[0034] FIG. 4A is an isometric view of the top side of the device shown in FIGS. 1A and 1B mounted to the rail shown in FIG. 2 in a first locked position.
[0035] FIG. 4B is an isometric view of the top side of the device shown in FIGS. 1A and 1B mounted to the rail shown in FIG. 2 in a second locked position.
[0036] FIG. 5A is an isometric view of the bottom side of the device shown in FIGS. 1A and 1B illustrating the device in a closed position wherein a resilient member urges a first base member into engagement with a second base member.
[0037] FIG. 5B is an isometric view of the bottom side of the device shown in FIGS. 1A and 1B illustrating the device in an opened position wherein a push rod member is being depressed to disengage the second base member from the first base member so that the device could be attached to or detached from a weapon accessory rail (not illustrated).
[0038] FIG. 6 is an isometric view of the top side of the device shown in FIGS. 1A and 1B illustrating the device in the opened position wherein the device is being attached to or detached from the rail shown in FIG. 2 and wherein the push rod member and two locating members are shown engaging transverse grooves of the rail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] Referring now to FIGS. 1A-6 , an exemplary embodiment of a mount adapter device in accordance with the present disclosure is illustrated and generally includes a push rod member 13 , a resilient member 22 , a first base member 11 , and a second base member 12 .
[0040] The push rod member 13 includes a knob 15 fastened to a first end 18 of a shaft 21 . The knob 15 includes a centrally threaded aperture 17 therein which allows the knob 15 to be rotated up and down the first end 18 of the shaft 21 of the push rod member 13 . The knob 15 may include a design such as the inverse U-shaped depressions 14 illustrated in the depicted embodiment. Such feature provides an attractive design and an additional gripping surface for rotating the knob 15 up and down the first end 18 of the shaft 21 . Furthermore, a sealing member 16 , such as a plastic gasket, may be disposed around a lower portion 63 of the knob 15 such that, upon assembly of the device 70 , the sealing member 16 may be interposed between the knob 15 and the first base member 11 when the knob 15 is rotated down to the bottom 65 of the first end 18 of the shaft 21 .
[0041] In the depicted embodiment, the shaft 21 of the push rod member 13 includes a first end 18 and a second end 20 which are divided by a central portion 19 . The first end 18 is threaded and is non-contiguous with the second end 20 which is also threaded. The first end 18 may include large threads 60 which have a greater major and minor diameter than the small threads 61 on the second end 20 of the shaft 21 . The large threads 60 on the first end 18 are designed to prevent the first end 18 of the shaft 21 from passing through a first aperture 62 in the first base member 11 , upon assembly of the device 70 . Additionally, the large threads 60 provide the device 70 with increased holding strength when the device 70 is in a second locked position, as represented in FIGS. 3 and 4B , which is discussed in detail below. The second end 20 is threaded to provide a means of fastening the push rod member 13 to the second base member 12 . The second base member 12 has a second aperture 29 therein which is internally threaded in order to receive and retain the second end 20 of the push rod member 13 .
[0042] The first 18 and second 20 threaded ends of the shaft 21 may be divided by a central thread-free portion 19 . Upon assembly of the device 70 , this thread-free portion 19 may be disposed on a lower mounting surface 25 of the first base member 11 so that this thread-free portion 19 projects from the lower mounting surface 25 (as shown in FIGS. 5A and 5B ) in order to engage an elected groove 40 of the rail 43 upon attachment of the device 70 to the rail 43 (as shown in FIG. 6 ).
[0043] In the depicted embodiment, the resilient member 22 is a spring which is received around the shaft 21 of the push rod member 13 and is captured between a lower portion of the knob 63 and a central recess 37 in a first lateral surface 23 of the first base member 11 . The resilient member 22 provides a spring force 64 which urges the first base member 11 into engagement with the second base member 12 such that when the device 70 is not being used it is in a closed position, as is represented in FIG. 5A .
[0044] The first base member 11 includes a first clamping member 46 having a first inclined proximal surface 32 adjacent to the lower mounting surface 25 and a first inclined distal surface 31 adjacent to the first inclined proximal surface 32 . The first base member 11 further includes a first engagement member 35 configured to engage the second base member 12 when the device 70 is in a closed position (shown in FIG. 5A ). Further, the first base member 11 includes an upper (in the orientation shown in FIGS. 2-4B and 6 ) portion 44 configured to receive and retain an accessory (not illustrated). In the depicted embodiment, the upper portion 44 includes a pair of apertures 27 allowing passage of a fastener through the aperture 27 for securing an accessory to the upper portion 44 . Other means for securing an accessory to the device 70 that are known in the art may also be used and are considered to be within the spirit and scope of the present invention. Additionally, the upper portion may be configured to receive and retain an additional rail structure to allow for direct attachment of an accessory to the additional rail structure.
[0045] The second base member 12 includes a second clamping member 47 that opposes the first clamping member 46 . The second clamping member 47 has a second inclined proximal surface 34 adjacent to the lower mounting surface 25 and a second inclined distal surface 33 adjacent to the second inclined proximal surface 34 . The second base member 12 further includes a second engagement member 36 configured to engage the first engagement member 35 of the first base member 11 when the device 70 is in a closed position (shown in FIG. 5A ).
[0046] As depicted in FIG. 2 , the opposing first 46 and second 47 clamping members are equal in length (that is, in the direction of the longitudinal axis 53 of the rail 43 ) and provide two opposing moving clamping forces 51 and 52 , which are approximately equal in magnitude, against opposite transverse edges 48 and 49 of the rail 43 . The two opposing moving clamping forces 51 and 52 come from two opposite directions 54 and 55 , which are transverse to the longitudinal axis 53 of the rail 43 .
[0047] The first 11 and second 12 base members are connected by first inserting the second end 20 of the shaft 21 of the push rod member 13 through a first aperture 62 in the first lateral surface 23 of the first base member 11 until the large threads 60 projecting radially from the first end 18 of the shaft 21 prevent the shaft 21 from being further received through the first aperture 62 . After the shaft 21 is slidably received through the first aperture 62 , the central portion 19 of the shaft 21 is positioned in a channel 28 , formed in the lower mounting surface 25 of the first base member 11 , which is configured and arranged for sliding engagement with the central portion 19 of the shaft 21 . The second end 20 of the shaft 21 is subsequently fastened to a second aperture 29 , which is internally threaded. The second aperture 29 is located in a second lateral surface 24 of the second base member 12 and is positioned to align with the first aperture 62 in the first base member 11 . The second aperture 29 is configured to receive and retain the threaded portion of the second end 20 of the shaft 21 of the push rod member 13 . Upon assembly, the resilient member 22 is received around the shaft 21 of the push rod member 13 and is captured between a lower portion of the knob 63 and a central recess 37 in the first lateral surface 23 of the first base member 11 .
[0048] In certain embodiments contemplated by this invention, locating members 26 may be optionally provided to limit the movement of the device 70 along the longitudinal axis 53 of the rail 43 . In the depicted embodiment, the mount adapter device 70 includes two locating members 26 fixed to the first base member 11 through apertures 38 formed therein. The locating members 26 are disposed on the lower mounting surface 25 of the first base member 11 . When the device 70 is installed on the rail 43 (as shown in FIG. 6 ), locating members 26 are configured to engage elected grooves 40 between mounting projections 50 in order to restrict any forward or backward movement of the device 70 along the longitudinal axis 53 of the rail 43 . The locating members 26 may define elongated rods as in the depicted embodiment, wherein a terminal end of each locating member 26 may extend past the lower mounting surface 25 of the first base member 11 (as shown in FIGS. 1A and 1B ) in order to be slidably received by a complimentary locating member aperture 30 located in the second base member 12 . Although the accompanying Figures illustrate the device 70 as including two locating members 26 , other embodiments are contemplated wherein greater or lesser numbers of locating members 26 are employed, zero locating members 26 being necessary.
[0049] A threaded set screw 45 may be threadedly received within an internally threaded set screw aperture 63 in the second base member 12 , as shown in FIG. 2 . The set screw 45 may be rotated until it bears against the second end 20 of the push rod member 13 so as to retain the push rod member 13 at a desired rotational position and to prevent disengagement of the push rod member 13 from the second base member 12 .
[0050] In operation, the first base member 11 is connected to the push rod member 13 in a manner that allows the first base member 11 to slide up and down the shaft 21 between the knob 15 and the second base member 12 , as shown in FIGS. 5A and 5B . The second base member 12 is threadedly fastened to the second end 20 of the shaft 21 so that the second base member 12 remains attached to the second end 20 of the push rod member 13 at all times. As shown in FIGS. 2 and 5A , the resilient member 22 provides a spring force 64 which urges the first base member 11 in a first direction 54 toward engagement with the second base member 12 , and which yieldably opposes movement of the first base member 11 in a second direction 55 toward the knob 15 . At the same time, the spring force 64 of the resilient member 22 bears against the lower portion 63 of the knob 15 which urges the push rod member 13 in a second direction 55 , opposite the first direction 54 . The second end 20 of the push rod member 13 is attached to the second base member 12 so that the spring force 64 simultaneously urges the second base member 12 along with the push rod member 13 in the second direction 55 . In this manner, as is represented in FIG. 2 , the resilient member 22 , in association with the push rod member 13 , creates two opposing and moving clamping forces 51 and 52 by urging the first base member 11 in the first direction 54 and the second base member 12 in the second direction 55 , which is opposite the first direction 54 . This forces the opposing clamping members 46 and 47 into locking engagement with the opposite transverse edges 48 and 49 of the rail 43 .
[0051] Rather than employ a single moving force coming from one direction, such as is seen in the prior art devices, the present invention locks to the rail 43 by employing two directly opposing moving forces 51 and 52 coming from two opposite directions 54 and 55 . This results in two opposing forces 51 and 52 , which are approximately equal in magnitude, being applied to the opposite transverse edges 48 and 49 of the rail 43 .
[0052] The spring force 64 provided by the resilient member 22 may be overcome by manually depressing the push rod member 13 to disengage the first base member 11 from the second base member 12 thereby moving the first 11 and second 12 base members into an opened position (as illustrated in FIG. 5B ). This increases the distance between the opposing clamping members 46 and 47 of the first 11 and second 12 base members. With the push rod member 13 depressed and the device 70 in the opened position, the device 70 is positioned on the rail 43 so that the lower mounting surface 25 bears against the upper mounting surfaces 39 of the mounting projections 50 and the central portion 19 of the shaft 21 of the push rod member 13 , along with any locating members 26 , is aligned and engaged with an elected transverse groove 40 on the rail 43 (as shown in FIG. 6 ).
[0053] The depressed push rod member 13 is then released which causes the resilient member 22 to decompress thereby forcing the first base member 11 in a first direction 54 toward engagement with the second base member 12 while simultaneously forcing the second base member 12 in a second direction 55 , opposite the first direction 54 , toward engagement with the first base member 11 . Movement of the first 11 and second base members 12 forces the opposing clamping members 46 and 47 to bear against the opposite transverse edges 48 and 49 of the rail 43 via two opposing and moving clamping forces 51 and 52 which come from two opposite directions 54 and 55 . In this manner, the device 70 provides for a first locked position (shown in FIG. 4A ) which allows the device 70 to be attached to the rail 43 in approximately 1 second by depressing the push rod member 13 , placing the device 70 on the rail 43 , and then releasing the push rod member 13 .
[0054] Furthermore, the push rod member 13 provides for a second locked position (shown in FIGS. 3 and 4B ). Starting from the first locked position with the device 70 attached to the rail 43 , the knob 15 is rotated down the first end 18 of the shaft 21 toward the first base member 11 until the lower portion of the knob 63 is adjacent the first lateral surface 23 of the first base member 11 . This second locked position fixedly locks the first base member 11 , along with the first clamping member 46 , and the second base member 12 , along with the second clamping member 47 , to the rail 43 . The second locked position provides the device 70 with maximum holding strength that is unparalleled and unheard of in this field.
[0055] FIG. 3 depicts the three points of contact that occur between the device 70 and a plurality of mounting projections 50 when the device is in the first locked position (shown in FIG. 4A ) or the second locked position (shown in FIGS. 3 and 4B ). The first clamping member 46 engages the first inclined distal surfaces 42 a of a plurality of mounting projections 50 , the second clamping member 47 engages the second inclined distal surfaces 42 b of a plurality of mounting projections 50 , and the lower mounting surface 25 bears against the upper mounting surfaces 39 of a plurality of mounting projections 50 . A small amount of space separates both the first clamping member 46 from the first inclined proximal surfaces 41 a of the mounting projections 50 and the second clamping member 47 from the second inclined proximal surfaces 41 b of the mounting projections 50 . This design allows the device 70 to fit any rail, including worn or disfigured rails. Moreover, the three-point contact provided for by the device 70 yields maximum holding strength which is unmatched by prior art devices.
[0056] In addition to providing an easy and quick attachment method, the device 70 also may be easily and quickly detached from the rail 43 . Starting in the first locked position (shown in FIG. 4A ), simply depress the push rod member 13 in a direction 54 that is transverse to the longitudinal axis 53 of the rail 43 . This disengages the opposing clamping members 46 and 47 from the rail 43 so that the device 70 is in the opened position (shown in FIG. 6 ) and may be simply lifted off the rail 43 .
[0057] While the present invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, the foregoing is considered as illustrative only of the principles of the invention and it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Once given the above disclosures, many other features, modifications, and variations will become apparent to the skilled artisan in view of the teachings set forth herein. Such other features, modifications, and variations are therefore considered to be a part of this invention, the scope of which is to be determined by the following claims.
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A mount adapter device is disclosed which utilizes a spring-loaded push system that employs a dual locking mechanism to releasably, consistently, and securely lock accessories to a weapon accessory rail. The mount adapter device generally includes a first base member, a second base member, a push rod member, and a resilient member. The push rod member slidably connects the first base member and the second base member. The first base member is linearly slidable into engagement with the second base member in a first direction, and the second base member is linearly slidable into engagement with the first base member in a second direction which is opposite the first direction. The first base member includes a first clamping member for engaging one edge of the rail. The second base member includes a second clamping member for engaging an opposite edge of the rail. The resilient member provides a spring force and is arranged to force the first clamping member to move in the first direction into locking engagement with the first edge of the rail while simultaneously forcing the second clamping member to move in the second direction into locking engagement with the second edge of the rail. A knob on the push rod member may be rotated down the push rod member to provide the device with a second locked position.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a 35 USC §371 national stage application of PCT/BR2014/000435, which was filed Dec. 10, 2014 and claimed priority to French Patent Application No. 1362395, filed Dec. 11, 2013, both of which are incorporated herein by reference as if fully set forth.
FIELD OF INVENTION
[0002] The invention refers to a combustion process for hydrocarbon materials in a thermal engine. The invention also refers to a thermal engine implementing and operating said process and system for producing energy from hydrocarbon materials comprising such engine.
[0003] The field of invention is the field of treatment of solid, liquid and/or gaseous hydrocarbon materials, particularly diesel. The invention specifically relates to diesel combustion and generally to hydrocarbon materials in a thermal engine.
BACKGROUND
[0004] The large majority of the systems of the state of the art performs combustion of said hydrocarbon materials with atmospheric air as oxidizing agent. We know that atmospheric air is constituted by 21% oxygen and 78% nitrogen, the balance being rare gases, and only oxygen (O 2 ) is the reactive element of combustion. Nitrogen is a neutral gas, which serves as ballast gas fluid, a thermal fluid and/or work volume expansion in current systems. Said systems are dedicated to the production of thermal energy (boiler shells, etc.) or to a conversion into mechanical energy (thermal engines, turbines, etc.).
[0005] To perform a complete combustion with atmospheric air, the oxidizing agent should be supplied in excess relative to the quantity of reactive oxygen. This equation results in the generation of disproportionate combustion gas volumes over the gases effectively produced by complete combustion. Further, considerable combustion gas volumes generate large inconveniences, considerable atmospheric pollution and effects (heat, organic pollutants, CO 2 , various oxides, aerosols, etc.) which neutralization is extremely difficult.
[0006] On the other hand, said large volumes of combustion gases become extremely costly means to be implemented to neutralize the generated pollution, especially the capture of CO 2 , which is one of the main causes of global warming.
[0007] These excessive oxidizing agents also reduce the transfer efficiency of energy of fuel energy to the system, and they usually do not perform complete combustion.
[0008] On the other hand, incomplete combustion of hydrocarbon materials in the current systems causes dirt deposition of non-burnt material, thus reducing yield of the current systems over time.
[0009] The sum of these inconveniences reduces the thermodynamic yield of current thermal engines, rarely surpassing 50% of the heating power of the fuel used, thus meaning waste of more than half of the available energy. Furthermore, a large part of the thermal energy is dissipated by the cooling systems of the engines and exhaust gases. Usually, the “global” yield of thermal engines is lower than 45% of the Lower Heating Power (PCI) of the fuel used.
[0010] Other processes promote a combustion of hydrocarbon materials with pure or eventually mixed dioxygen with a neutral gas such as CO 2 , e.g., like the process as disclosed by the document EP 2,383,450 A1. These proceedings enable to increase yield, reduce the quantity of pollutant particles and facilitate the capture of CO 2 from the combustion gas generated by the combustion.
[0011] However, it is still possible to increase combustion yield and improve combustion conditions to achieve a more respectful way of combustion, particularly the thermal engine wherein the combustion is performed.
[0012] One of the objects of the invention is to provide a combustion process of hydrocarbon materials in a thermal engine, so to allow for a better yield.
[0013] Another object of the present invention is to provide a combustion process of hydrocarbon materials in a thermal engine, which is more respectful than the thermal engine of the current processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other advantages and characteristics will emerge after examining the detailed description of non-limitative embodiments and the attached drawings, wherein:
[0015] FIG. 1 is a schematic representation of a first embodiment of a thermal engine according to the invention;
[0016] FIG. 2 is a schematic representation of a second embodiment of a thermal engine according to the invention; and
[0017] FIG. 3 is a schematic representation of a system to produce energy from hydrocarbon materials according to the invention, by embodying and operating the engine of FIG. 2 .
DETAILED DESCRIPTION
[0018] The invention enables to reach at least one of the objects as already explained, by means of a combustion process of solid, liquid or gaseous hydrocarbon materials in a thermal engine comprising at least one combustion chamber, said process comprising at least one interaction of the following steps constituting a combustion cycle:
[0019] introduction in said combustion chamber of a load of hydrocarbon materials and a oxidizing gaseous mixture; and
[0020] triggering of combustion of said load of hydrocarbon materials with said oxidizing gaseous mixture;
[0021] wherein said oxidizing agent comprises:
[0022] trioxygen (O 3 ); and
[0023] carbon dioxide (CO 2 ) and/or carbon trioxide (CO 3 ).
[0024] As “hydrocarbon materials,” we understand petroleum, petroleum derivatives, natural and synthetic petroleum gases, coals and/or biomass, as well as all residues containing carbon and/or hydrocarbon, and synthesis gases from decomposition and gasification of said hydrocarbon materials.
[0025] As oxygen, we understand the oxygen atom (O) which, in current formulations, composes the dioxygen molecule (O 2 ) and the trioxygen molecule (O 3 ), usually called “ozone.”
[0026] As “thermal engine,” we understand every device performing the combustion of hydrocarbon materials and producing mechanical or electric energy.
[0027] The process of the invention provides a combustion of hydrocarbon materials with an oxidizing gaseous mixture comprising trioxygen (O 3 ) and more particularly negative trioxygen (O 3 − ).
[0028] The use of trioxygen in the oxidizing gas allows for a better use of each oxygen (O) element and consequently a more complete combustion of hydrocarbon material.
[0029] In fact, as will be disclosed below, the use of trioxygen increases the flammability of hydrocarbon materials by destabilizing the cohesion of their molecules and by speeding up the oxidization of the atoms in their compositions.
[0030] Furthermore, due to the increase in the flammability of the hydrocarbon material by using trioxygen, the combustion of hydrocarbon material is facilitated in terms of temperature and/or pressure, preserving the thermal engine or means operating combustion.
[0031] According to a first embodiment of the process of the invention, the oxidizing gas can solely comprise trioxygen (O 3 ) and carbon dioxide (CO 2 ) and/or carbon trioxide (CO 3 ).
[0032] According to a second embodiment of the process of the invention, the oxidizing gas can also comprise dioxygen (O 2 ).
[0033] Whichever is the embodiment of the process of the invention, trioxygen is dosed for each atom of fuel organic material (C and H) to have the number of oxygen (O) atoms as required for a stoichiometric combustion. Trioxygen present in the oxidizing gas (alone or mixed with dioxygen O 2 ), thermo-chemically interacts with fuel organic materials of multiple form.
[0034] Trioxygen reacts firstly with CO 2 in the oxidizing gaseous mixture according to the reaction:
[0000] CO 2 +O 3 CO 3 +O 2 (1).
[0035] Subsequently, trioxygen reacts with the organic materials, which act with catalysts according to the reaction:
[0000] O 3 +catalyst→catalyst+O catalyst+O 2 (2).
[0036] Said interactive bonds are unstable and kept in the order of milliseconds during combustion.
[0037] If the oxidizing gas comprises carbon trioxide (CO 3 ), generated by the reaction (1), the latter instantaneously loses (during the combustion) its third O atom in the form of negative ion (O − ), which is also immediately captured by a hydrocarbon fuel molecule. The same happens with trioxygen (O 3 ), from which the surplus oxygen atom is extracted and immediately fixed by an organic catalyst (C or H) of the hydrocarbon molecule, thus creating a free pathway for its parent molecule of O 2 .
[0038] Said instantaneous and simultaneous interactions increase the flammability of catalyst fuels by destabilizing the cohesion of their molecules and speeding up the oxidization of atoms of their composition.
[0039] The integrity of oxygen available is the heart and the reaction agents. The combustion is complete, with maximum yield with the right measurement of oxygen.
[0040] With the process according to the invention, the lower flammability limit is optimized by factor 5 (five) and the speed of deflagration is doubled relative to atmospheric combustion. Oxidizing conditions make flammability conditions become instantaneous, as well as the thermal generation, thermal transmission and the expansion of the gas volume.
[0041] Providing for a complete combustion of hydrocarbon materials, thermal yield as obtained from the process according to the invention is better than that of the processes and/or engines of the state of the art. Furthermore, the thermal engine is not subject to the dirt deposition of non-burnt material, thus considerably increasing the working life of the system in comparison with the processes of the state of the art.
[0042] The combustion gas, as a result of the combustion, is composed only by CO 2 and H 2 O, with eventual residual O 2 molecules. The CO 2 is the complete combustion carbon molecule, stable at high temperatures, above 800° C. H 2 O is the molecule resulting from the complete combustion of hydrogen from the molecular composition of the hydrocarbon material, said H 2 O is easily recoverable by condensation, even at atmospheric pressure and temperature. Said two molecules are recyclable and allow recovering most of the dissipated energy of the combustion and reduce the ecological impact on the environment, thus eliminating gaseous pollutants, notably nitrogen oxides, which cannot exist in the absence of nitrogen.
[0043] On the other hand, the oxidizing gas has constant characteristics for any geographic or atmospheric variations (air humidity and altitude). Therefore, quantities can be precise and constant under any circumstances, so to provide for linear and permanently regulated combustion.
[0044] According to the invention, the load of hydrocarbon materials as required for the combustion can be mixed with at least one component of the oxidizing gas before being introduced into the combustion chamber, e.g., with CO 2 and/or CO 3 , or even with pure O 3 or eventually with O 2 .
[0045] The oxidizing gas can be injected in the combustion chamber before, after or simultaneously with the introduction of the load of hydrocarbon material into the combustion chamber.
[0046] CO 2 and/or CO 3 and pure O 3 or eventually mixed with O 2 can be separately injected in the combustion chamber, or all of them can be mixed together before the injection in the combustion chamber.
[0047] In the process according to the invention, the combustion can be performed with:
[0048] applying a pressure in the combustion chamber; and/or
[0049] supplying electrical energy to said combustion chamber;
[0050] e.g., with a spark plug as known by the expert in the art.
[0051] The process according to the invention can also comprise the injection of a quantity of liquid water in the combustion chamber before, after or simultaneously with the oxidizing gas. Therefore, up to 20% of water relative to the oxidizing gas and preferably between 5% and 20% of water relative to the oxidizing gas can be introduced into the combustion chamber as a function of the thermal regulation as scheduled or desired and the water expansion capacity into steam, which will replace its equivalent into CO 2 and/or CO 3 .
[0052] The injection of water allows regulating the combustion temperature, since it absorbs a large quantity of energy from combustion into latent heat, thus reducing thermal losses caused by the dissipation in the cooling and combustion exhaust gas circuits. The injected liquid water represents a negligible volume ratio with the oxidizing gaseous mixture of less than 20% as a function of the size of the thermal system at issue. Once amidst the combustion medium, said water evaporates into overheated steam. The expansion of the volume of liquid water as converted into steam is more than 10 times to hundreds of times the value introduced as a function of the dynamic pressure as impinged.
[0053] Therefore, latent heat of evaporation is completely and immediately transformed into useful thermodynamic energy, instead of having a considerable part of it dissipated by the cooling and combustion gas exhaust circuits. The portion of injected water is limited by lowering the temperature caused by its evaporation and which should not be lower than the optimal operating temperature of the thermal system at issue. The volume of the portion of evaporated water replaces the equivalent volume of CO 2 /CO 3 .
[0054] The oxidizing gas can comprise between 15 and 25% of oxygen, in the form of pure O 3 or in the form of a mixture of O 3 and O 2 , and between 85 and 75% of CO 2 and/or CO 3 .
[0055] More particularly, the oxidizing gas can comprise between 18 and 22%, preferably 21% of oxygen in the form of pure O 3 or in the form of a mixture of O 3 and O 2 , and between 82 and 78%, preferably 79%, of CO 2 and/or CO 3 .
[0056] The oxidizing gas advantageously comprises, for a mole of carbon of hydrocarbon material, at least one mole of CO 2 and/or CO 3 , and a maximum of 17 moles of CO 2 and/or CO 3 .
[0057] The oxidizing gaseous mixture advantageously comprises, for one carbon atom of the hydrocarbon material, at least the equivalent to two oxygen atoms and a maximum of the equivalent to 102% of oxygen, in the form of pure O 3 or in the form of a mixture of O 3 and O 2 .
[0058] The oxidizing gas can advantageously comprise for a hydrogen (H) atom in the hydrocarbon material, at least one oxygen atom in the form of pure O 3 or in the form of a mixture of O 3 and O 2 , and a maximum of the equivalent to 102% of oxygen in the form of pure O 3 or in the form of a gas mixture of O 3 and O 2 .
[0059] When the oxidizing gas comprises pure trioxygen, the latter may be obtained from a pure O 3 reservoir/tank. When the oxidizing gas comprises trioxygen mixed with dioxygen, the mixture can be obtained either from a reservoir/tank containing a mixture of O 3 and O 2 , or from a reservoir containing pure O 3 and a reservoir containing pure O 2 .
[0060] Alternatively, the process according to the invention can also comprise a step of generation of trioxide from oxygen molecules, more particularly from dioxygen molecules (O 2 ), e.g., by the “CORONA” effect applied to the oxygen molecules, more particularly to dioxygen molecules.
[0061] For that purpose, the process according to the invention can implement a production mean of trioxygen (O 3 ).
[0062] Trioxide generating means can comprise a “CORONA” effect device, installed, e.g., on a conduit in which oxygen (O 2 ) flows, such as the injection tube of dioxygen O 2 into the combustion chamber, to induce electric conversion discharges according to the formula:
[0000] O 2 +hv →O 2 *( 3 Σ u − );
[0063] (170 to 210 nm);
[0000] O 2 *+O 2 →O 3 +O, O+O 2 →O 3 .
[0064] The ratio of oxygen to be converted is defined by the intensity of the induced Corona effect, and the portion of O 3 can vary between 10 and 100% of the oxidizing oxygen as included in the gaseous oxidizing mixture.
[0065] Furthermore, the process according to the invention can comprise a step of generation of carbon trioxide CO 3 from CO or CO 2 molecules, and preferably from CO 2 molecules, e.g., by means of the “CORONA” effect applied to the CO 2 molecules in the presence of O 3 /O 2 .
[0066] According to a preferred embodiment, the oxidizing gas is obtained from a gaseous mixture of O 2 and CO 2 , to which Corona effect is applied to generate O 3 and CO 3 molecules, the oxidizing gas therefore, obtained comprises:
[0067] O 3 ; and
[0068] CO 2 or CO 3 or a mixture of CO 2 and CO 3 ; and
[0069] eventually O 2 , as a function of the energy of the electric discharges applied for the Corona effect.
[0070] As disclosed above, the combustion gas obtained after the combustion essentially comprises CO 2 and H 2 O steam .
[0071] The process according to the invention can also comprise a recovery of CO 2 included in the combustion gas, by cooling said combustion gas.
[0072] When the combustion gas comprises H 2 O molecules, steam can be previously removed from the combustion gas by condensation, and then, CO 2 and the latent heat from condensation can be recovered.
[0073] Advantageously, CO 2 can be condensed by any/all process known by the expert in the art. Therefore, all non-condensable material originated from the fuel and/or from the oxidizing gaseous mixture (metals, metalloids, sulfur, oxygen) are isolated from CO 2 , which is pure in liquid stage, and can be stored and recycled in the process. CO 2 can be evaporated during the cooling process of the combustion gas before being re-injected into the combustion chamber for a new cycle.
[0074] Thermal energy (thermal capacity/sensitive and latent heat) of the combustion gas can also be recovered, by means of heat exchange with a thermal fluid with one or more heat exchangers, e.g., aiming to produce electricity with a turbine.
[0075] A part of CO 2 recovered from the combustion gas of a combustion cycle can be advantageously re-used in the oxidizing gas and/or to generate carbon trioxide as disclosed above, to perform a new combustion cycle.
[0076] A part of CO 2 recovered from the combustion gas can be re-used in a microalgae culture, e.g., in a microalgae reactor, wherein the microalgae culture provides O 2 by means of photosynthesis.
[0077] At least a part of O 2 provided by microalgae can be used in the oxidizing gas and/or to generate trioxygen as disclosed above, for a new combustion cycle.
[0078] According to another aspect of the invention, it is provided a thermal engine performing a combustion of hydrocarbon materials, and particularly organized means to operate all the steps of the combustion process according to the invention. The thermal engine according to the invention can comprise trioxygen generating means from oxygen atoms, more particularly from a gaseous flow of O 2 .
[0079] Said carbon trioxide generating means can comprise means applying Corona effect with oxygen atoms, more particularly with a gaseous flow of O 2 , e.g., a Corona effect tube disposed on a duct in which O 2 flows.
[0080] The thermal engine according to the invention can also comprise means to generate carbon trioxide from CO molecules or preferably from CO 2 molecules.
[0081] Said carbon trioxide generating means can comprise means to apply Corona effect on CO molecules or preferably on CO 2 molecules, e.g., a Corona effect tube disposed on the duct in which CO 2 flows in the presence of O 3 /O 2 .
[0082] The thermal engine according to the invention can further comprise at least one adjustment module for the:
[0083] quantity of CO 2 and/or CO 3 ; and/or
[0084] quantity of oxygen in the form of pure O 3 or a mixture of O 3 and O 2 ;
[0085] used in the oxidizing gas.
[0086] The thermal engine can also comprise at least one adjustment module of the quantity of liquid water introduced into the combustion chamber and eventually an adjustment module of the quantity of hydrocarbon materials for each combustion cycle.
[0087] According to another aspect of the invention, it is provided a vehicle with a thermal engine according to the invention to move the vehicle. Said vehicle can be, e.g., a boat or a train.
[0088] According to another aspect of the invention, it is provided a system for producing mechanical or electrical energy from hydrocarbon materials, comprising:
[0089] a thermal engine according to the invention, supplying a combustion gas comprising CO 2 ; and
[0090] at least one microalgae reactor producing O 2 by photosynthesis;
[0091] at least one means for feeding said reactor with at least a part of CO 2 present in said combustion gas; and
[0092] at least one means for recovering at least a part of said O 2 produced by said microalgae reactor and reusing said recovered O 2 to generate trioxygen.
[0093] It is understood that the embodiments described below will not be limitative. We can notably imagine variations of the invention comprising only a selection of the characteristics described below, isolated from the other characteristics as described, if this selection of characteristics is sufficient to confer a technical advantage or to show the difference between the present invention over the state of previous art. This selection comprises at least one preferable functional characteristic with no structural details, or only with a part of the structural details if this part is sufficient only to confer a technical advantage or to distinguish the invention unique enough over the state of the prior art.
[0094] In the drawings, the elements common to several figures keep the same reference.
[0095] FIG. 1 is a schematic representation of a first example of an engine according to the invention.
[0096] The engine 100 as represented by FIG. 1 comprises, in a similar way to thermal engines currently known, a plurality of cylinders 102 1 , 102 2 , . . . , 02 n . Each cylinder 102 comprises a piston, respectively referenced 104 1 , 104 2 , . . . , 104 n , mobile in translation and defining in each cylinder a combustion chamber 106 1 , 106 2 , . . . , 106 n . Each piston 104 is pushed in translation by the combustion in the combustion chamber, of a fuel product, allowing the rotation of a transmission shaft 108 , as known in current thermal engines.
[0097] The engine 100 comprises, for each cylinder 102 and for each combustion cycle:
[0098] a first module 110 i , adjusting the quantity of hydrocarbon materials HC introduced into the combustion chamber 106 , from a reservoir 112 of hydrocarbon materials;
[0099] a second module 1141 , dosing the quantity of oxygen introduced into the combustion chamber 106 , in the form of pure O 3 or a mixture of O 3 and O 2 ;
[0100] a third module 116 , dosing the quantity of pure CO 2 , pure CO 3 or also CO 2 mixed with CO 3 , introduced in the combustion chamber 106 ;
[0101] a forth module 118 , dosing the quantity of liquid H 2 O as introduced into the combustion chamber 106 from a H 2 O reservoir 120 .
[0102] The engine 100 also comprises a corona effect tube 122 , located at the outlet of a reservoir of O 2 124 , allowing generating a gas flow constituted by pure O 3 or by a mixture of O 3 and O 2 , from O 2 provided by the reservoir 124 . The gas flow obtained downstream from the corona effect tube 124 (and constituted by pure O 3 or a mixture of O 3 and O 2 ) feeds the module 114 i to regulate the quantity of oxygen, and then its injection into the combustion chamber 106 i .
[0103] The engine 100 also comprises a corona effect tube 126 , located at the outlet of a reservoir of CO 2 128 , allowing generating a gas flow composed by pure CO 3 or a mixture of CO 3 and CO 2 , from a part of CO 2 provided by the reservoir 128 and from the O 2 provided by the reservoir 124 . The gas flow obtained downstream from the corona effect tube 126 feeds the module 1161 to regulate the quantity of CO 3 and CO 2 , followed by its injection into the combustion chamber 1061 .
[0104] Combustion of the mixture formed by the load of materials (hydrocarbons+oxidizing gas) is activated by the combustion chamber 106 or by pressure applied by the piston or by a spark plug (not shown), producing an electric spark in the combustion chamber.
[0105] The combustion gas obtained from the complete combustion of the load of hydrocarbon materials with oxygen entering the combustion chamber 106 is evacuated by an evacuation tube/conduit 130 . The combustion gas GC is mainly constituted by CO 2 . On one hand, the CO 2 admitted into the combustion chamber 106 through the module 116 and, on the other hand, CO 2 formed by the oxidization of carbon elements C present in hydrocarbon compounds by the O 3 compounds (and possibly O 2 ), and H 2 O, on one side H 2 O eventually admitted in the combustion chamber 106 by the module 118 and, on the other side, H 2 O formed by the oxidization of the di-hydrogen elements H 2 present in the hydrocarbon compounds.
[0106] It is possible that the combustion gas GC includes residual compounds of O 2 , e.g., in a ratio of 1 or 2% of combustion gas, excessively admitted in the combustion chamber 106 to assure complete combustion of the load of hydrocarbon materials HC in the combustion chamber 106 .
[0107] FIG. 2 is the schematic representation of a second embodiment of an engine according to the invention.
[0108] The engine 200 as represented by FIG. 2 resumes all the elements and configuration of engine 100 of FIG. 1 .
[0109] Besides the engine 100 of FIG. 1 , the engine 200 comprises a treatment module 202 of the combustion gas GC installed in the extraction conduit 130 for combustion gases.
[0110] The treatment module comprises a thermal exchanger (not shown) performing a thermal exchange between the combustion gas GC to take the combustion gas GC to a temperature lower than 100° C. so to condensate H 2 O steam contained in the combustion gas GC. Therefore, the steam found in the combustion gas GC is isolated and feeds the water reservoir 120 to be re-used in the next combustion cycle.
[0111] When the combustion gas GC includes residual O 2 , the latter one, which is not condensable at the condensation temperature of CO 2 , is isolated by means of CO 2 condensation and feeds the reservoir of O 2 124 to be re-used in the next combustion cycle.
[0112] Finally, after separating steam from O 2 , the combustion gas GC only contains CO 2 feeding the reservoir 128 of CO 2 to be re-used in the next combustion cycle.
[0113] FIG. 3 is a schematic representation of a system for producing energy from hydrocarbon materials according to the invention, by operating the engine of FIG. 2 .
[0114] The system 300 for producing energy of FIG. 3 comprises the thermal engine 200 of FIG. 2 .
[0115] Besides the thermal engine of FIG. 2 , the system 300 comprises a microalgae reactor 302 , receiving, through a conduit 304 , a part of CO 2 extracted from the combustion gas GC by means of the module 202 . Said microalgae reactor 302 produces O 2 by photosynthesis. A conduit 306 captures O 2 produced by the microalgae reactor 302 for feeding the reservoir of O 2 124 for use in a next combustion cycle.
[0116] In all the examples disclosed, the invention allows to produce mechanical energy by rotating the shaft 108 .
[0117] Said mechanical energy can, for instance, be used to move a vehicle on the ground, in the air or water, such as a boat. In this case, the thermal engine can be, as a non-limitative example, a diesel engine fed by a petroleum derivative such as heavy fuel oil.
[0118] Mechanical energy can also be used to generate electric energy, e.g., with an electric generator moved by an engine and/or gas turbine and/or liquid hydrocarbons and in combination with a steam turbine alternator.
[0119] In all the examples disclosed, modules 110 , 114 , 116 and 118 can be configured to introduce in the combustion chamber 106 , respectively, a pre-determined quantity of hydrocarbon materials HC, oxygen in the form of pure O 3 or mixed with O 2 , CO 2 /CO 3 and liquid water, said quantities being determined in accordance to, on one hand the quantity of carbon C and hydrogen H molecules present in the load of hydrocarbon materials admitted into the combustion chamber, so that the load of hydrocarbon materials suffers a complete combustion, i. e. a complete oxidization, and on the other hand, the size of the cylinder 102 and piston 104 and the desired power at the engine output.
[0120] Each one of the modules 110 , 114 - 118 can be an electronic module controlled by computer.
[0121] In all the examples disclosed, each combustion element is separately admitted into the combustion chamber 106 . Consequently, it is also possible to mix at least two elements of combustion before admission into the combustion chamber 106 and submit them to thermal and/or mechanical treatment, e.g., compression.
[0122] In all disclosed cases, each combustion element can suffer thermal treatment or compression before being admitted into the combustion chamber.
[0123] In the examples described, the corona effect tube 126 is optional and the oxidizing gas may not contain CO 3 .
[0124] Alternatively, one single corona effect tube can be used instead of tubes 122 and 126 . In this case, the O 2 provided by the reservoir 124 is mixed with the CO 2 provided by the reservoir 128 , after the gaseous mixture O 2 +CO 2 is transported by one single corona effect tube.
[0125] We now describe a combustion of hydrocarbon materials according to the invention, when the hydrocarbon material is solely constituted of hexadecane with the formula C 16 H 34 , in comparison with a combustion under atmospheric air.
[0126] The table below shows the characteristics of hexadecane C 16 H 34 :
[0000]
Characteristics of hexadecane molecule (Cethane) C 16 H 34 (ratio per kg)
molar mass
= 226.44 g/mol
= 4.42 moles/kg
PCS
oxygen (O 2 ) useful for complete
combustion (stoichiometric)
C 16
C = 70.66 moles/kg
CO 2 : 394 kJ/mol
oxygen O 2
= 70.66 moles/kg
= 27 839.36 kJ/kg
H 34
H 2 = 75.075 moles/kg
H 2 O: 242 kJ/mol
oxygen O 2
= 37.54 moles/kg
= 18 168.01 kJ/kg
Total
= 46 007.37 kJ/kg
Total
= 108.20 moles/kg
= 12.78 kWh/kg
Oxygen (O 2 ) p/kg C 16 H 34
molar mass:
= 32.00 g/mol
Total
= 3.46 kg/kg
= 2.425 Nm3/kg
[0127] Wherein it describes that:
[0128] 1 kg of hexadecane has a higher heating value (PCS) of 12.78 kWh and a lower heating power (PCI) of 11.48 kWh≈˜9%;
[0129] The complete oxidization of 1 mole of carbon in 1 mole of CO 2 generates an exothermic reaction of 394 kilojoules, while the incomplete oxidization of 1 mole of carbon into 1 mole of CO only generates an exothermic reaction of 111 kilojoules, i.e., 3.55 times less;
[0130] Each particle is carbon and each gram of carbon can generate 32.83 kilojoules of thermal energy with 1 mole of carbon=12 g.
[0131] The “thermodynamic” yield of an explosion engine, with controlled ignition or compression Otto or Diesel is relative to the combustion yield and the transfer from thermal energy to mechanical energy.
[0132] The present invention optimizes combustion yield and, consequently to reduce fuel consumption, for identical energetic product.
[0133] Combustion at “atmospheric” air depends on atmospheric (humidity) and geographic factors (altitude, oxygen-poor air). In Diesel engines, at constant volumes, the quantity of oxidizing air is constant and must be oversized to offer the best combustion. The quantity of interactive oxygen in air is not higher than 65% of 21% of oxygen existent in the air, at sea level. To reach the oxygen of the stoichiometric combustion, we need to double the volume of oxidizing air. The volume of combustion air interacts with the combustion providing active oxygen, but, on the other hand, increasing the volume of neutral gas (nitrogen), which acts in the opposite direction reducing the combustion zones since it takes space.
[0134] One of the advantages of the process, according to the invention is that the trioxygen molecule can be produced on the site of its use with several possibilities of quantitative and qualitative regulation.
[0135] Another advantage of the process, according to the invention is that the trioxygen molecule is unstable and it immediately interacts with its medium, provided that it contains “catalyst” organic materials or that its electric polarity (negative/positive) is opposed to that applied to the ozone. The prime interaction between trioxygen with the carbon dioxide molecule in the gaseous oxidizing mixture, before its injection in the combustion chamber, generates carbon trioxide (CO 3 ). The binding of the third oxygen atom and the CO 2 molecule is very unstable. Any proximity with an organic material causes the catalytic reaction of transferring said atom to the organic material; the capture of said oxygen atom, actives the destabilization of the catalyst molecule. Said partial oxidization makes the compounds of the organic molecule more oxidative and more flammable.
[0136] The gaseous oxidizing mixture (O 2 /O 3 +CO 2 /CO 3 ) interacts directly with the fuel.
[0137] The instability of the trioxygen bindings and their immediate capture by the organic catalysts create an “autogenous” pre-combustion of the fuel materials, oxygen then interacts directly with fuel under more favorable conditions than the usual combustion/oxidization, without the fact that being mixed with CO2/CO3 hampers this reaction, which is exothermal.
[0138] Another advantage of the process according to the invention is that the injection of water into the combustion chamber with the oxidizing gaseous mixture favors the distribution of the fuel front flame. In that highly exothermic medium and under temperatures above 1000° C., CO 2 /CO 3 and H 2 O also interact directly with the fuel by means of a “redox” reaction, which helps distribute and speed up combustion.
[0139] In atmospheric combustion, numerous carbon particles are not burned, thus hydrocarbon molecules, which have not been oxidized by the mixture of combustion air.
[0140] In the process, according to the invention, atomic and molecular oxygen reacts directly with the fuel and decomposes the hydrocarbon molecule in oxidizing C and H. At the same time, a “redox” reaction is activated by CO 2 and H 2 O of the mixture, which also react with C and H of the decomposed molecules of the following redox reactions:
[0000] C+CO 2 2CO+172 kJ/mol;
[0000] H 2 +CO 2 H 2 O+CO+41 kJ/mol.
[0141] These reactions are endothermal; they take part in the regulation of the temperature of the medium and reduce thermal dissipation. The reaction (C+CO 2 2CO) gasifies carbon structures and amorphous carbon elements (particles, soot) which would not be directly oxidized by O 2 . Therefore, they are converted into gaseous molecules (CO) that are more reactive to complete oxidation (eminently more flammable because of their gaseous state, which causes CO molecules to have a better distribution in front of the flame(s) of the thermal system and by of the thermochemical conditions of the medium) in the presence of free oxygen:
[0000] CO+O CO 2 −283 kJ/mol.
[0142] Therefore, completion of combustion is progressive during the thrust (work) period of the engine pistons, which increases thermodynamic capacity for a same unit of fuel, improves the linear efficiency by distributing thermal effects throughout the course of said piston, and thus reduces wear due to thermal differentials, reducing global thermal dissipation.
[0143] The same thing happens to the H 2 O molecule that react with CO according to:
[0000] H 2 O+CO H 2 +CO 2 −41 kJ/mol; and
[0000] H 2 +O H 2 O−242 kJ/mol.
[0144] Therefore, completion of combustion is progressive during the thrust (work) period of the engine pistons, increasing thermodynamic efficiency by homogenization of thermal distributions by these sequences of simultaneous exothermal reactions.
[0145] Another advantage of the process according to the invention is that the mixture of CO 2 /oxygen does not generate pollution by nitrogen oxide, since nitrogen molecules are not present in the combustion.
[0146] In the present example, the fuel is hexadecane, of formula C 16 H 34 , the average density of this fuel is ≦1.
[0147] As disclosed on the table, to perform the stoichiometric combustion of 1 liter of hexadecane, 3.46 kg of oxygen (O 2 ) (2.425 Nm 3 ) are required.
[0148] For atmospheric combustion with 50% efficiency yield with the characteristics of the current processes and engines, one must consider the volume of air as a function of the efficiency coefficient of separation O 2 from the nitrogen mixture, approximately 60/65%.
[0149] To reach the combustion yield of said engines, an excess of oxygen of at least 15% is required, i.e.:
[0150] 3.98 kg or 2.79 Nm 3 of O 2 .
[0151] Considering an efficiency coefficient of separation of O 2 of 65%:
[0152] 2.79/65%=4.29 Nm 3 of O 2 .
[0153] Considering a 21% percentage of O 2 per m 3 of air:
[0154] 20.43 Nm 3 of air per liter of hexadecane.
[0155] This combustion has only 50% of efficiency.
[0156] An engine is designed then in function of these parameters. Current engines work with a proportion of ⅕ of oxygen in the oxidizing mixture (the same ratio as in air).
[0157] The process according to the invention only requires an excess of O 2 between 2 and 5% for a combustion yield higher than 93%, i.e.:
[0158] 3.57 kg or 2.50 Nm 3 of O 2 .
[0159] Since there is no constraint linked to the separation of the gaseous mixture, oxygen is totally active. Combustion yield is maximized.
[0160] Complete combustion of carbon generates CO 2 and 3.6 times more energy than that produced by incomplete combustion in CO:
[0000] C+O=CO 111 kJ/mol;
[0000] C+O 2 ═CO 2 394 kJ/mol.
[0161] This state of fact provides energy from a better expansion of the combustion gas.
[0162] CO 2 substitutes nitrogen as ballast gas for thermal gaseous expansion that supplies mechanical work pushing the piston.
[0163] At 800° C., CO 2 has a dilatation coefficient 30% higher than air, thus requiring 23% less of the thermal capacity (heat sensitive).
[0164] From this, if we compare “atmospheric” values, transposed to O 2 /CO 2 , we have:
[0165] 20.43 Nm 3 of air per liter of hexadecane less oxidizing oxygen “2.425 Nm 3 of O 2 ” (see table)=18 Nm 3 of ballast gas (nitrogen+rare gases).
[0166] At 800° C., said 18 Nm 3 of ballast gas represent 48.021 m 3 for a thermal capacity of 9.283 kWh. 1 kg of hexadecane has a lower heating power (PCI) of 11.48 kWh, thus representing combustion yield of 80.86%.
[0167] 18 Nm 3 of ballast gas CO 2 :
[0168] At 800° C., said 18 Nm 3 substituted by CO 2 expand into 62.654 m 3 for a thermal capacity of 7.174 kWh.
[0169] About 15 m 3 of exceeding “work” capacity.
[0170] 1 kg of hexadecane has a lower heating power (PCI) of 11.48 kWh, which leave more than 4 kWh of exceeding thermal energy, i.e.:
[0171] The capacity to generate about 35 m 3 of CO 2 at 800° C., i.e., cumulated an exceeding total of 50 m 3 of CO 2 at 800° C.
[0172] Alternatively:
[0173] 1 kg of hexadecane+2.425 Nm 3 of O 2 +18 Nm 3 of CO 2 produce two times more work capacity than 1 kg of hexadecane in atmospheric combustion.
[0174] Or also:
[0175] ½ kg of hexadecane+1.213 Nm 3 of O 2 +9 Nm 3 of CO 2 produce the same work as 1 kg of hexadecane in atmospheric combustion.
[0176] Another example, 1 kg of hexadecane contains 70.66 moles of carbon (see table). The minimum CO 2 (to justify an ideal Boudouard reaction homogenizing the combustion) is 70.66 moles of CO 2 , i.e., at least 1.6 Nm 3 of CO 2 (approximately) and maximum of 27 m 3 of CO 2 to exploit 95% of the lower heating power (PCI) of 1 kg of hexadecane: the value for a given engine depends on the type of engine, i. e. the engine cubic capacity, piston course, etc., this value being between these two numbers.
[0177] Additionally, a small part of the CO 2 ballast may be substituted by “liquid” water injected at the same time as O 2 and CO 2 of the gaseous oxidizing mixture.
[0178] This addition may happen in order to:
[0179] regulate the combustion temperature absorbing a large quantity of energy in latent heat to transform it into dynamic energy by volume expansion of steam; and
[0180] homogenize the combustion by the redox reaction which can occur during the change of state (liquid/steam) if the H 2 O molecule of steam is near a CO molecule. Said exothermal reaction releases a di-hydrogen (H 2 ) molecule in the medium that will react in any way with the oxygen of said medium, either with a free (O) atom or with an (O) atom of a trioxidized molecule;
[0181] reduce thermal loss by dissipation, latent heat is recovered during steam condensation by the cold heat carrier (liquid and/or gaseous CO 2 , oxygen, liquid water).
[0182] The process according to the invention reduces the wear of the equipment, maintenance; the whole combustion gas produced is recyclable:
[0183] H 2 O is condensable into distilled water;
[0184] CO 2 is partially recycled for re-use in the process according to the invention; and
[0185] excess CO 2 and H 2 O can be recycled in a microalgae culture plant, which will then produce hydrocarbon materials and oxygen.
[0186] Anyway, the invention is not limited to the examples disclosed above.
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The invention relates to a process of combustion of solid, liquid or gaseous hydrocarbon (HC) raw materials in a heat engine comprising at least one combustion chamber, said process comprising at least one iteration of the following steps, which constitute/form a combustion cycle, wherein a load of hydrocarbon (HC) materials and an oxidizing gas are added to said combustion chamber, combustion of said load of hydrocarbon materials being triggered by said oxidizing gas; characterized in that said oxidizing gas comprises: trioxygen (O 3 ) and carbon dioxide (CO 2 ) and/or carbon trioxide (CO 3 ). The invention likewise relates to a heat engine for carrying out and conducting the process according to the invention, and to a system for producing energy from hydrocarbon materials by implementing and operating such engine.
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BACKGROUND
[0001] In the downhole industry, boreholes and various levels of completion are used for many different operations. Many of these completions have long lifespans and sometimes the lifespan of the completion is greater than the life of a particular well in which it is installed. In other words, there may be a desire to rework a well before the completion is beyond its actual useful life. Such can be the case with older wells that are not instrumented leading an owner to consider a rework of the well at significant expense and down time. As will be immediately recognized by one of ordinary skill in the art, more instrumentation faster and for less money and downtime would be well received.
SUMMARY
[0002] A through tubing intelligent completion including a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed.
[0003] A method for upgrading an existing well with an intelligent completion including making up a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; running the completion string into a production tubing string in a borehole; exiting a downhole end of the production tubing string with the completion string; and deploying the one of more isolation seals.
BRIEF DESCRIPTION OF THE DRAWING
[0004] Referring now to the drawings wherein like elements are numbered alike in the several figures:
[0005] FIG. 1 is a schematic view of a borehole system as disclosed herein;
[0006] FIG. 2 is an enlarged view of one of the control valves in accordance with the teaching hereof
DETAILED DESCRIPTION
[0007] Referring to FIG. 1 , a borehole system 10 having a tubing string 12 that may be preexisting or may just be preinstalled is illustrated. A through tubing system is taught herein that allows installation of an intelligent completion through an existing tubing string 12 , such as production tubing into an open hole 14 . The through tubing completion 16 includes a string 18 one or more isolation seals 20 (three shown) and one or more flow control devices 22 (three shown) which in one embodiment will mirror the number of isolation seals 20 . These components are run on a capillary coil tubing 24 or similar conveyance through the tubing string 12 and into, in one embodiment, an open hole.
[0008] Recognizable to one of ordinary skill is a restriction 26 , representing one or more possible restrictions in the tubing string 12 . This presents a significant hurdle with respect to running a through tubing intelligent completion such as that depicted in the Figures hereof. In order to have a useful through tubing completion 16 , it must be of reasonable size (for example, for a tubing string 12 of 4.5 inch diameter, the restriction 26 will in one instance be 3.75 inches. Accordingly the completion string 18 must have an outside diameter of less than 3.75 inches). Currently available interventionlessly actuatable flow control devices cannot be used while maximizing the completion string size. For purposes of clarity, “interventionlessly” as used herein is intended to mean that a tool need not be run to adjust the valve but rather that adjustment may be done remotely based upon input from a control line or autonomously. Types of control lines contemplated include electric, hydraulic, optic, etc. In accordance with the present invention however, the inventors hereof have solved this persistent problem.
[0009] The through tubing intelligent completion 16 provides both zonal isolation and control in a through tubing package. Isolation seals 20 are, in one embodiment, high expansion packers that may be inflatable or swellable, for example, and are hence capable of having a very diminutive diameter prior to deployment allowing them to pass the restriction 26 . The control devices 22 must similarly pass through the restriction. As noted above, actuatable devices heretofore were not able to pass through the restriction except for sliding sleeves that require surface intervention by a shifting tool to open or close. The interventionlessly actuable flow control devices of the present invention however, include on board actuators that can be actuated electrically, hydraulically, optically, magnetically pneumatically, etc. and in some embodiments can be actuated automatically pursuant to a controller nearby the device 22 . Each of the devices 22 includes a housing 30 having an actuator 32 centrally located therewithin. The actuator in a central position in the housing is made possible by the lack of a central flow channel, which was heretofore common in the art. Rather than trying to retain the central flow channel as would one of ordinary skill in the art and push the actuator to the side of the housing, resulting is a larger overall diameter, the inventors hereof have followed an unconventional path. The devices 22 disclosed herein take advantage of the shapelessness of fluid to reduce the overall housing size. More particularly, the fluid flow that is to be conveyed through the device, bypass flow 46 , as distinct from the flow that is selectively admitted or denied entry to the completion 16 through the valve (discussed below), is diverted around the actuator 32 in one or more channels. Although this is represented in FIG. 2 with one bypass flow channel 46 , it is to be understood that such channels may be perimetrically located around the actuator and housing. The same overall flow area is achieved by that of a central flow area device but since the flow is spread out it can be thinner in radial dimension and hence allow for the actuator to be housed without increasing housing dimension.
[0010] The housing 30 includes, in one embodiment, a poppet type or similar valve 34 having a poppet 36 in operable communication with the actuator 32 and a seat 38 . The poppet valve 34 and seat 38 are interposed between an orifice 40 and a flow channel 42 that is in communication with a tubing flow channel 44 . Flow through the valve 34 is commingled with bypass flow 46 for delivery uphole in the embodiment where the borehole is intended to produce. The valve 34 may be opened, closed or choked to serve the overall purpose or optimization of flow into or out of the completion 16 . Note too that the valve 34 is interventionlessly actuable to selectively admit or deny (or choke) fluid from a particular area while not affecting the fluid flowing through the bypass 46 . This therefore allows the selective control of areas or zones of the borehole while not having a resultant effect on other zones or areas that was common with prior art completions. In addition to the flow control, the intelligent completion may also in some embodiments include one or more sensors 48 configured to sense one or more parameters associated with the borehole to optimize production. The one or more sensors 48 may be located anywhere that is convenient along the completion string.
[0011] The through tubing completion system as described is capable of passing through the restriction 26 in tubing 12 and thereby facilitates the delivery of an intelligent completion system through an existing tubing string which may have been from a preexisting borehole system or a newly created one where it has been determined that an intelligent completion downhole of an installed tubing string would be beneficial. As one of skill in the art will recognize, the ever-changing conditions in the downhole environment provide ample opportunity for such an upgrade or change in plan.
[0012] At a relative uphole end 50 of the completion 16 , a set of one or more ports 52 are provided that allow fluid flowing in the completion 16 to exit the tubing 18 and thereby flow into the production tubing 12 for production to the surface.
[0013] Finally, it will be noted that the completion 16 is provided, in one embodiment, with a control line 60 that is supplied with a signal (of whatever type may be propagated by the particular type of control line) through a wet connect 62 that connects to a control line 64 from surface.
[0014] The system of the invention provides dramatically enhanced functionality over a tubing 12 alone and allows for retrofitment in older wells created before intelligent completions were ubiquitously accepted.
[0015] While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
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A through tubing intelligent completion including a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed and method.
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FIELD OF INVENTION
The invention relates to window coverings and particularly to a window covering having a cellular structure with strips or slats connected between two parallel faces of material through which light may pass.
BACKGROUND OF THE PRIOR ART
Venetian blinds are well-known window coverings. They have a series of horizontal slats hung from ladders which extend between a top rail and a bottomrail. The slats can be rotated between an open, see through position and a closed position. Additionally, the blinds can be raised and lowered. Venetian blinds contain aluminum, plastic or wood slats and are available in a wide range of colors.
Fabric window coverings and draperies are often preferred by consumers over venetian blinds because they have a softer, warmer appearance. However, draperies do not have the ability to control the amount of light transmitted through the window covering in a manner similar to louvered blinds like the traditional venetian blind.
Several attempts have been made to provide a fabric window covering with the ability to control the amount of light entering the room. Shapiro in U.S. Pat. No. 3,851,699 discloses a window draw drape having spaced apart light impeding and light transmitting vertical sections. The light impeding sections can be rotated to cover all or portions of the light admitting sections. The light impeding sections are vertical slats attached to the drapery or tightly woven fabric. The light admitting sections are open mesh. This product is difficult to operate because the light impeding sections tend not to align with the light admitting portions when those sections are rotated.
In U.S. Pat. No. 5,313,999 to Colson et al. there is a window covering having first and second parallel sheer fabric sides and a plurality of light impeding or somewhat light impeding vanes extending between the sheer fabric sides. The vanes are angularly controllable by relative movement of the sheer fabric sides. Like the combination of a sheer fabric and a light impeding fabric this system allows the user to have a fully open window, a sheer covered window allowing light transmission with day time privacy, and a more opaque covering providing night time privacy or room darkening. In addition, it has intermediate light control of a louvered product like venetian blinds. The Colson window covering system is difficult to manufacture and to fabricate, has a limited range of fabrics it can use, and has a very flat appearance when in the light impeding mode. Another problem with this window covering is that a moire appearance often occurs on the front face of the window covering as a result of an alignment between the weave pattern of the front sheet and the weave pattern of the rear sheet. When this window covering is attached to a roller, the material tends to crumple or wrinkle when rolled up. The material is also hard to cut and the cut edges are difficult to seal because of the sheer fabrics that must be used.
Another light control window covering system is disclosed in U.S. Pat. No. 3,384,519 to Froget. The window covering disclosed there consists of two cloth layers spaced apart by movable parallel blades having each of their marginal edges heat welded to one of the movable cloth layers. Froget's welding uses the material present which is very thin in order to be see-through, flexible, and store well. It is difficult to precisely apply heat and pressure to sufficiently bond these layers without damaging them by melting through the layer or forming warp spots. With this window covering relative movement of the two cloth layers in a direction perpendicular to the blades changes the angle of the blade and thus controls the amount of light emitted through the article. Because the blades must be heat welded to the cloth layers, only thermoplastic materials can be used. Also, heat welding necessarily requires a melting of some of the fibers of the material bonded, thus providing an uneven outer appearance along the heat welds and producing unwanted crimps or creases of the material which can result in fatigue failure. Furthermore, heat welding is a relatively slow process and the resulting weld is limited in strength. The window covering material in the Colson and Froget blinds is tilted and stored on a roller wrapping successively around itself. When the layer is displayed over the window the front layer is the same length as the back layer. When the layers are stored around the roller each layer travels a progressively larger or longer path, the difference depending on the thickness of each fabric. Since all the layers are bonded together the wrapping can cause wrinkling on the layers traveling on the inside or shorter paths. Having very uniformly thin layers helps mitigate this problem, but requiring thin layers limits the variations of the weave, yarns, style and other fabric features that can be chosen.
In my U.S. Pat. No. 5,339,882, I disclose a window covering having a series of slats connected between two spaced apart sheets of material. The slats are substantially perpendicular to the sheets of material when the covering is in an open position. The slats are substantially parallel to the first and second sheets of material when the window covering is in a closed position. This product has many of the same limitations of the window covering disclosed by Colson and Froget. All these products use sheets of fabric and have all the problems associated with fabric sheets.
In U.S. Pat. No. 5,753,338 Jelic et al. disclose a honeycomb material for window coverings in which the front face, back face and slats are interwoven simultaneously. This process uses an improved warp knitting technique in which a front mesh and a rear mesh are provided and warp threads are woven through them. The two meshes are maintained parallel to one another. At selected intervals slats are woven between the two meshes to form a honeycomb structure. Since the warp threads weave back and forth between meshes, it would seem almost impossible for the slat to have a greater density than the “faces.” Secondly, since the material is created with the slats being perpendicular to the meshes, the slats must bend to affect the closure, but they have no hinge portion. This window covering has not been commercialized, but one would expect it to have the same problems as the window covering disclosed by Colson.
A problem with these fabric structures is that they must be very precisely made to look and function properly. But, textiles are inherently inconsistent and unprecise due to the nature of the weaving, printing and coating processes. Changes in temperature and humidity cause fabric to expand and contract. If a sheet of fabric is hung between a headrail and a bottomrail, a change in temperature or humidity may cause the edges of the fabric to move inward. Such movement is severely restrained near the headrail and the bottomrail, but can more easily occur around the center of the fabric. Consequently, the fabric sheet will assume an hourglass shape. For many fabrics this hourglass appearance is quite noticeable, particularly for longer shades. One way in which the art has been able to address this problem is to avoid using many fabrics for window coverings that will be subject to wide ranges of temperature and humidity. Some fabrics can be coated with starch or other chemicals to prevent shrinkage. But, that treatment increases costs.
There is a need for a window covering system which provides the light control of a venetian blind with the soft appearance of draperies and pleated shades. This window covering should be available in a wide variety of fabric, colors and styles. The window covering should not be adversely affected by changes in temperature and humidity. The window covering should be suitable for use on a roller or with lift cords to raise and lower the shade. The window covering should be able to be easily cut down from standard sizes and to be otherwise easy to fabricate. The system should be simple to install and to operate and able to be manufactured at a cost which allows the product to be sold at a competitive price. Furthermore, the window covering should not suffer from the moire effect that has plagued the window coverings which have two parallel sheets of light transmissive material. Finally, the widow covering should be easy to clean and maintain.
SUMMARY OF THE INVENTION
I provide a light controllable window covering in which there is a transparent front face formed from a series of spaced apart parallel threads. The back face is also transparent and can be made from knitted or woven material or could also be a series of spaced apart parallel thread. A series of opaque slats are attached between the two faces. The slats are preferably a knitted or woven fabric treated to have a given light impeding property. The front longitudinal edge of each slat is attached to the front face and the rear longitudinal edge of each slat is attached to the back face. The resulting structure when combined with a hardware system is a light control honeycomb window covering.
The parallel threads which form the front face are spaced apart from the back face an amount which allows light to readily pass while providing a soft fabric like appearance. Consequently, movement of the light impeding slats from a position perpendicular to the front face and back face to a position generally parallel to the front face and back face controls the amount of light which is admitted through the window covering.
The slats can be made from a single fabric which is woven or knitted or a nonwoven or a laminated combination that is flexible in at least the transverse direction. If desired the slats could also be a plastic, metal or even wood material. Longitudinal or transverse stiffeners may be provided on the slats.
The window covering made in this way can be attached to a roller or to a headrail and have lift cords routed through or adjacent the slats. A third layer of any type of material could be used with this window covering. That third layer could be adjacent the back face or the front face of the honeycomb structure. That layer could be raised and lowered independently or in conjunction with the other layers.
Other objects and advantages of the invention will become apparent from a description of certain present preferred embodiments shown in the drawings.
DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a first present preferred embodiment of my light control window covering in an open position.
FIG. 2 is a side view of the window covering of FIG. 1 in a closed position.
FIG. 3 is diagram showing a preferred method of making the embodiment of my light control window covering shown in FIGS. 1 and 2.
FIG. 4 is a front view of a second present preferred embodiment.
FIG. 5 is an end view of a third present preferred embodiment.
FIG. 6 is a sectional view taken along the line VI—VI of FIG. 5 .
FIG. 7 is an end view of a fourth present preferred embodiment,
FIG. 8 is a perspective view of the embodiment shown in FIG. 1 modified so that the bottomrail is a first rail attached to the front face and a second rail attached to the back face.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first present preferred embodiment of my light control window covering 1 shown in FIGS. 1 and 2 has a front face 2 , a back face 4 and a series of slats 6 connected between them to form a honeycomb structure 1 . The bottom rail 10 may be one piece, as shown in FIG. 1, or may consist of a first rail 10 a attached to the front face and a second rail 10 b attached to the back face, as shown in FIG. 8 . The front and back faces extend from headrail 8 to bottomrail 10 . In this embodiment, the front and back faces are a series of spaced apart parallel warp threads 3 . There is a sufficient distance between adjacent threads to allow light to readily pass through the front and back faces. The spacing preferably is from 0.080 to 0.25 inches. However, to make the threads easily visible a greater spacing is shown in the figures. Using the warp threads alone for front and back faces minimizes the thickness of the structure when the honeycomb is in a closed position. This triple layer flattened honeycomb structure can be flattened to a theoretical minimum. Another advantage to using only warp threads, or using warp threads with relatively few weft treads, is that the warp threads can move toward and away from one another into the space between adjacent threads. Consequently, the threads can assume a sine wave shape when the window covering is rolled onto a roller. In this way the layer can shorten as needed to avoid wrinkling. A knit or woven fabric cannot do this. Use of parallel threads also increases transparency so that another more decorative, layer that may not be connected to the other layers can be placed on the front. Yet, another advantage of a parallel thread layer is that the slats can more easily be cleaned. A vacuum brush run over the face of the window covering can pull dust or bugs from the slats, between the parallel threads and into the vacuum cleaner.
Many of these same advantages can be obtained when one of the two layers is a knit or woven material. Consequently, in another embodiment of the present window covering, either the front face 2 or the back face 4 may be knit or woven material which permits passage of light through the material. A series of slats which are opaque or nearly opaque are attached to either or both of the front and back faces by adhesives or welding using any conventional attachment method. Slats could be lace or could be sheer with the intention of putting ribbons on top of the slats. These louvers enable the user to have a variable range of light pass through the window covering. The upper end of the range may just be a translucent level of light or it might be a black out. In most embodiments the slats likely will be semi-opaque.
As shown in FIG. 3 I prefer to form the honeycomb structure in manner similar to the process disclosed by Froget in U.S. Pat. No. 3,384,519. Two supply rolls 11 and 12 are provided. One roll 11 contains a series of threads, 3 each thread wound in a separate coil on the roll 13 . The second supply roll 12 may be identical to the first roll 10 or it may be a knit fabric 14 or woven material wound on a roller. A series of slats 6 are placed on the advancing fabric 14 from supply 17 . The slats are made of a flexible material or have a flexible or hinged edge. One edge of each slat is bonded to the fabric 14 . The opposite edge of the slats is bonded to the parallel threads. In a preferred embodiment the slats 6 are first attached to the fabric 14 . A glue line 15 is placed on the edge of the slat which is away from the fabric. The parallel threads 3 are fed over a grooved roller 16 . Then the parallel threads 3 , fabric 14 and slats are passed between rollers 17 and 18 where the threads 3 are attached to the slats. In one embodiment the adhesive 15 is melted by heated rollers 17 and 18 . In another embodiment a two part adhesive is used. One part forms the glue line 15 and the other part is applied to the threads. Glue line 15 need not extend the full length of the slats, but could be a series of spaced apart droplets or short lines of adhesive. Thermoplastic ribs can be added to the edges of the slats to increase the amount of material available for welding onto the warps and also to enhance the rigidity of the slats on the edges so that there can be a longer span between warp threads. Such ribs will prevent the hour glass stretching of the product. Transverse stiffeners could also be provided on the slats.
The threads which form the front and back faces preferably will be a polyester but can be any type of thread that has been used in window covering fabrics. The slat also should be a polyester but other materials, such as polyester films and laminates that can be used. Another option is to use a copolyester hot melt adhesive which is tacky at a lower temperature, typically around 220° F., and melts and flows at a higher temperature, usually around 350° F. While the adhesive is tacky the slats can be easily positioned. When properly positioned the temperature can be raised to melt the adhesive and then quickly cooled to complete the bond.
The honeycomb structure could be attached to the bottom of the headrail in the same manner as are many conventional pleated shades. One option is to provide a mandrel 24 within the headrail. The front and back faces are oppositely connected to the mandrel 24 . Rotation of the mandrel in either direction will move the back face relative to the front face tilting the slats. In this manner the orientation of the light impeding slats are moved from a position perpendicular to the front and back faces as shown in FIG. 1 to a position nearly parallel to the front and back faces such as is shown in FIG. 2 . Lift cords 5 preferably extend from the bottomrail 10 into the headrail 8 . A lift mechanism (not shown) within the headrail raises and lowers the window covering. The lift cords 5 can be placed only along the back of the window covering as shown in FIG. 2, along both the front and the back, or as shown by chain line 5 a through apertures in the slats. In an alternative configuration the window covering could be rolled onto the mandrel to raise the window covering from a lowered to a raised position. When the shade is fully lowered rotating the mandrel will move the slats from a horizontal, open position toward a vertical closed position.
The use of parallel threads in the front face and the back face prevent the appearance of a moire pattern which is caused by a misalignment of two sheets of light transmissive fabric having the same or similar weave. If desired one could provide a series of widely spaced apart cross threads or weave threads through the parallel threads 3 to create a pleasing design or pattern such as large circle 11 in the front face and smaller circle 12 in the back face as shown in FIG. 4 . However, these cross threads must not be so frequent as to create a woven material. Indeed, the number of cross threads should never be more than one-tenth of the number of parallel threads. A single thread which crosses back and forth across the parallel warp threads would be considered as a separate cross thread each time that it crosses the warp threads. If a large number of cross threads are provided in both the front face and the back face, then there likely will be the moire effect that this window covering is designed to avoid. Cross threads affect the cutting for width, the rolling on the roller, the transparency, the moire, but mostly the manufacturability of the product since knitted goods lack dimensional consistency as do woven sheers in wide widths. It is less costly saving machine time and material by not having cross threads.
A third embodiment of the window covering 30 shown in FIGS. 5 and 6 has a honeycomb structure 32 similar to the previous embodiments and an additional layer 34 with bottomrail 39 . The layer 34 in this embodiment is independent from the cellular structure 32 . Layer 34 can be a pleated shade, a roman shade or a sheet of material wound on an independent roller. Preferably the independent roller 34 is adjacent the front of the cellular structure 32 and is a knit or lace material. The front 31 of the cellular structure is a series of parallel warp threads and the back 33 is a knit material or a series of parallel warp threads. The lift cords are positioned in spaces between adjacent parallel warp threads in the front face. Loops 36 are provided on the slats 3 for each lift cord. Stiffeners 37 and 38 may also be provided on each slat.
A fourth embodiment 40 as shown in FIG. 7 is similar to the third embodiment. This window covering 40 has a cellular structure 42 and additional layer 44 . In this embodiment lift cords 45 run from the bottomrail 36 of the cellular structure. The additional layer 44 has tabs or loops through which the lift cords 45 pass. Consequently, raising the cellular structure 42 also raises the additional layer 44 .
Use of the additional layer provides several advantages. Any material suitable for use in a window covering could be used for the additional layer. Consequently, the front layer could be any color or texture and have any weave or pattern. This is possible because the additional layer is not part of the multi-layer cellular structure and is not bonded to any other material. In a multi-layer cellular material one's choice of materials is limited by fabrication concerns and compatibility of fabrics. The material for the front layer must not stretch much more or less than the material selected for the back layer or wrinkling will occur. Some materials are difficult to bond to other materials. Cost is always a concern. In the present preferred embodiments the cellular structures can be made of a relatively inexpensive material while the additional layer can be more expensive fabric.
In all the embodiments one can clean slats through the front face of parallel warp threads. Any additional layer could easily be lifted or rolled-up to allow access through the layer of parallel warp threads. The present invention minimizes thickness of front and back faces that are attached to the slats, minimizes visual contributions of faces and increases transparency. In the present window covering the slat is a more dominant visual component for color and texture. The faces of the cellular structure are so thin, inexpensive and transparent that an additional layer of decorative material can be added in the front. It is also easier to cut across the width of a layer without fraying or welding adjacent layers.
In describing the preferred embodiments the terms front face and back face have been used to distinguish the faces of the cellular structure. It should be understood that when the cellular structure is attached to the headrail or placed over a window opening, either face may be facing the window. Consequently, front face is not limited to the room side of the window covering and back face is not limited to the side of the window covering nearest the window.
Although I have shown several present preferred embodiments of my window covering, it should be distinctly understood that the invention is not limited thereto but may be variously embodied within the scope of the following claims.
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A light controllable window covering has a transparent front face and a transparent back face, either or both of which are formed from a series of spaced apart parallel threads, and a series of opaque slats attached between the two faces. The parallel threads which form the front face and back face are spaced apart an amount which allows light to readily pass while providing a soft fabric like appearance. The slats are preferably knitted or woven fabric treated to have a given light impeding property. The front and back longitudinal edges of each slat are respectively attached to the front face and the back face. The resulting structure when combined with a hardware system is a light control honeycomb window covering. Movement of the light impeding slats from a position perpendicular to the front face and back face to a position generally parallel to the front and back face controls the amount of light which is admitted through the window covering. An additional layer may be provided opposite the front face or the back face.
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FIELD OF THE INVENTION
[0001] The invention relates to hair and grooming brushes, and, more particularly to self-cleanable brushes.
BACKGROUND OF THE INVENTION
[0002] Brushes of various types, such as hair brushes and pet grooming brushes, suffer from the problem of becoming clogged with loose hairs, fur, and other debris that may become entangled amongst the bristles of the brush while the brush is being used.
[0003] Users may try to remove the hair by using a comb or another brush, if one is available, or by hand. However, these methods are often time-consuming and inconvenient, sometimes even exposing the user to a risk of injury by sharp bristles, in part because hair and fur may easily become entangled amongst the bristles. Thus, it can be difficult to remove the debris in essentially one manipulative motion, which can be desirable, especially when grooming a pet who is trying to escape confinement.
[0004] Self-cleanable brushes that include a perforated plate with holes that can slide over the bristles of a brush may be limited to brushes with bristles configured to emerge from a backing member perpendicularly to the backing member, among other limitations. Such self-cleanable brushes may thus not be suitable for pet grooming brushes that frequently include bristles extending from a backing member at an angle. Such self-cleanable brushes may also become difficult or impossible to use when bristles become bent or are no longer in their original perfect alignment, as can be caused by the wear-and-tear of normal brush use.
[0005] Furthermore, self-cleanable brushes that include removable and/or disposable parts are not usable when the removable parts are misplaced or replacements for disposable parts are not readily available.
SUMMARY OF THE INVENTION
[0006] The present invention addresses the foregoing problems by providing a self-cleanable hairbrush for use on animals or humans that has a frame with strands extending across it, allowing for easy removal of fur, hair, and other debris while remaining tolerant of non-perpendicular bristles and other deviations and imperfections in the bristles that may arise from the wear-and-tear of normal use. In one embodiment, the frame is attached to the brush by a pivoting hinge and may be pivoted by the hinge to a position in which the frame is seated flat against a bristle-side of the brush, allowing the strands to slip between the bristles and the frame to be secured in place. In other embodiments, the frame is formed as an integral part of the brush or brush handle. In some embodiments, the strands and frame are formed as an integral unit.
[0007] As the brush is used, loose hairs, fur, or other debris may become entangled in the bristles. Releasing the frame and allowing it to swing up through the bristles gathers the entangled debris and removes it from bristles, allowing it to be disposed of. The frame and strands may then be re-seated against the bristle-side of the brush, leaving the brush cleaned and ready for re-use.
[0008] In various embodiments, the strands may be configured in a variety of patterns to fit easily between the bristles of the brush. For example, the strands may be configured as parallel lines, as a grid of perpendicular strands, as a set of diagonal lines, or in another suitable configuration. The strands may be formed of wire, plastic, or other material that allows the strands to slip easily between the bristles and to support the collect debris without breaking.
[0009] Embodiments of the self-cleanable brush further include a handle that is rotatable to various positions within a full circle and that may thus allow the user to find a position that reduces hand strain and that allows for a more comfortable and efficient use of the brush.
[0010] An embodiment of a brush is described that comprises a brushing element, a cleaning element, and a pivoting hinge. The brushing element includes a bristle head and a multiplicity of bristles extending from the bristle head. The cleaning element includes a frame and strands extending across the frame. The pivoting hinge mounts the frame to the bristle head, allowing the frame to swing across the bristles when the brush is being used and to swing away from the bristles when the brush is being cleaned, such that when the frame swings across the bristles, the frame lies substantially flat against the bristle head and the strands lie between the bristles. When the frame swings away from the bristles, the strands carry away any debris that may have collected amongst the bristles during use of the brush.
[0011] An embodiment of a method of cleaning a hair brush is described. The method comprises the acts of: providing a hair brush that has a bristle head and a releaseably attached strand frame attached by a hinge to the bristle head; and allowing the strand frame to pivot about the hinge, lifting up out of the bristles debris from the bristle head that has collected on the strand frame.
[0012] For purposes of summarizing the invention, certain aspects, advantages and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features of the invention will now be described with reference to the drawings summarized below. These drawings and the associated description are provided to illustrate preferred embodiments of the inventions, and not to limit the scope of the invention. Like reference characters designate the same or similar parts throughout the several views.
[0014] FIG. 1A shows a front view of one embodiment of a self-cleanable brush with a cleaning frame opened.
[0015] FIG. 1B shows a view from below of one embodiment of the self-cleanable brush with the cleaning frame opened.
[0016] FIG. 2 shows a side view of one embodiment of a self-cleanable brush with the cleaning frame closed.
[0017] FIG. 3 shows top views of one embodiment of the self-cleanable brush with a rotatable handle positioned in a variety of positions.
[0018] FIG. 4A is a top-view of one embodiment of the self-cleanable brush.
[0019] FIG. 4B is a cross-section view of one embodiment of the self-cleanable brush showing a rotating mechanism for rotating the handle of the brush.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] A self-cleanable brush is disclosed that allows a user to easily remove hair, fur, or other debris that may have collected amongst the bristles of the brush during use. Embodiments of the brush may be used as hair brushes, pet grooming brushes, or other types of brushes.
[0021] The self-cleanable brush will now be disclosed with reference to the accompanying figures in which like numerals refer to like parts.
[0022] FIGS. 1A and 1B show two views of one embodiment of a self-cleanable brush 10 . FIG. 1A shows a front view of the brush 10 , and FIG. 1B shows a view of the brush 10 from below. The embodiment of the self-cleanable brush 10 depicted in FIGS. 1A and 1B comprises a bristle head 20 , bristles 30 , a handle 70 , and a cleaning frame 40 .
[0023] The bristle head 20 shown in FIG. 1 is of a generally rectangular shape. In other embodiments, the bristle head 20 may be of another shape. For example, the bristle head 20 may be generally oval-shaped, square, or round. For some embodiments in which a user grasps the bristle head 20 manually during brushing, the bristle head 20 may be kidney-bean-shaped or other shape that ergonomically fits a user's hand and is comfortable to hold.
[0024] The bristle head 20 may be made of metal, plastic, rubber or other suitable material, such as wood or molded synthetic resin.
[0025] As illustrated in FIG. 1A , the bristle head 20 has a bristle-side 25 and a back-side 15 . The bristle-side 25 has a plurality of bristles 30 extending therefrom, the bristles 30 generally parallel to one another. The bristles 30 are embedded at one end and extend perpendicularly from the bristle head 20 . In other embodiments, the bristles may extend from the bristle head 20 at an angle. The bristles 30 may be made of metal, plastic, rubber, or other suitable material. In some embodiments, particularly those used for pet grooming, the bristles may be densely packed wire bristles of metal or other similarly strong material.
[0026] In the embodiment of the self-cleanable brush 10 shown in FIGS. 1A and 1B , the handle 70 that a user grasps to manipulate and control the brush 10 is attached to the back-side 15 of the bristle head 20 . In other embodiments, the handle 70 may be attached to the bristle head 20 along an edge of the bristle-head 20 or in another position that allows a user grasping the handle 70 to manipulate the brush 10 . In still other embodiments, the brush 10 does not have a handle 70 , and the user grasps the bristle head 20 from the back-side 15 directly when using the brush 10 . In some embodiments, the handle 70 is rotatably attached to the bristle head 20 , as will be described in greater detail with reference to FIG. 3 .
[0027] The cleaning frame 40 of the self-cleanable brush 10 as depicted in FIGS. 1A and 1B is of substantially the same perimeter shape as the bristle head 20 and may be made of plastic, metal, or other suitable material. The cleaning frame 40 is attached to the bristle head 20 along one side of the bristle head 20 by one or more pivoting hinges 75 or other pivoting mechanism. The pivoting hinges 75 allow the cleaning frame to swing away from the bristle-side 25 of the bristle head 20 , as is depicted in FIGS. 1A and 1B . The pivoting hinges 75 also allow the cleaning frame 40 to swing up against the bristle-side 25 of the bristle head 20 . A latching mechanism 65 on the cleaning frame 40 , generally opposite the pivoting hinges 75 , is configured to engage with the bristle head 20 to align and releaseably attach the cleaning frame 40 to the bristle head 20 . In one embodiment, there is a ridge on the surface of the bristle head 20 for releasably engaging the latching mechanism 65 .
[0028] The cleaning frame 40 includes strands 50 extending across it that may be configured in any one of a variety of configurations. In several preferred embodiments, the strands are generally parallel to one another. In various embodiments, the strands 50 may be stretched across the cleaning frame 40 from side to side relative to the frame 40 or in a lengthwise direction relative to the frame 40 . In some embodiments, some strands 50 may be stretched across the cleaning frame 40 in a side to side direction and some strands 50 are stretched across the cleaning frame 40 in a lengthwise direction, thereby forming a crossing matrix or grid of strands 50 stretching across the cleaning frame 40 . In other embodiments, the strands 50 may extend diagonally with reference to the cleaning frame 40 or may be configured in another configuration that corresponds to a configuration of the bristles 30 .
[0029] When the cleaning frame 40 is attached to the bristle head 20 , the strands 50 on the cleaning frame 40 easily slip between the bristles 30 to sit substantially against the bristle head 20 at the base of the bristles 30 , allowing the bristles 30 to extend normally from the bristle head 20 . The strands 50 may be spaced so as to allow many bristles 30 to extend between adjacent strands 50 , thereby allowing the allowing the cleaning frame 60 and the strands 50 to tolerate deviations in the bristles 30 , such as bristles 30 that are somewhat bent or misshapen due to wear-and tear of brush use. The brush 10 may then be used in a normal fashion, for example, to groom a pet or to brush hair.
[0030] When the bristles 30 of the brush 10 become clogged with matted fur, hair, or other debris, the latching mechanism 65 of the cleaning frame 40 may be disengaged from the bristle head 20 , allowing the cleaning frame 40 to swing away from the bristle head 20 . As the cleaning frame 40 swings away from the bristle head 20 , the strands 50 of the cleaning frame 40 are drawn up through the bristles 30 , bringing the fur, hair, or debris up with it past the bristles 30 , where the fur, hair, or debris collected on the strands 50 may be removed and disposed of. The cleaning frame 40 may then be replaced and the latching mechanism 65 re-engaged, leaving the brush 10 clean and ready for re-use.
[0031] In one embodiment, the handle 70 is split down its length into two sections that are joined at the end of the handle by the pivoting hinge 75 . A first section of the handle 70 may be connected to the bristle head 20 may be integral to the bristle head 20 , and a second section of the handle 70 may be connected to the cleaning frame 40 or may be integral to the cleaning frame. The pivoting hinge 75 may be closed so that the two sections join to form a single handle 70 during use and may be opened to separate the cleaning frame 40 from the bristle head 20 for cleaning.
[0032] FIG. 2 shows a side view of one embodiment of a self-cleanable brush 10 with the cleaning frame 40 closed.
[0033] FIG. 3 shows top views of one embodiment of the self-cleanable brush 10 with a rotatable handle 70 positioned in a variety of positions. In some embodiments, it may be desirable to adjust the position of the handle 70 relative to the bristle head 20 . For example, when using the brush 10 to groom a pet with thick fur, the fur may cause resistance, thus increasing strain and fatigue of the hand, arm, and/or wrist of the person using the brush 10 . Changing the position of the handle 70 may allow the user to find an orientation which reduces the strain. Furthermore, the three-dimensional and non-uniform nature of an animal's body surfaces which a user may desire to groom present additional challenges that may be alleviated by adjusting the position of the brush handle 70 relative to the bristle head 20 and the bristles 30 .
[0034] The embodiment depicted in FIG. 3 provides for eight different handle positions relative to the bristle head 20 that together allow the handle 70 to circumscribe an arc of three-hundred-and-sixty degrees in intervals of forty-five degrees.
[0035] In other embodiments, the handle 70 may be positionable in a different set of positions, or may be positionable at any point in a three-hundred-sixty-degree arc. Furthermore, in still other embodiments, the handle 70 of the brush 10 may be non-rotating and may be attached to the bristle head 20 in a fixed manner or may be an integral part thereof.
[0036] FIG. 4A is a top-view of one embodiment of the self-cleanable brush 10 , and FIG. 4B shows a cross-section view of one embodiment of the self-cleanable brush 10 showing a rotating mechanism for rotating the handle 70 of the brush 10 . As illustrated in FIGS. 4A and 4B , the handle has a circular base 71 with a circular lip 72 that extends downwards and that may be seated in a circular channel 73 formed in the back-side 25 of the bristle head 20 . The handle 70 is held in place by a spring lock screw 74 . In the floor of the circular channel 73 may be recesses, and in the bottom of the circular lip may be one or more protrusions that can fit into the recesses to form detents for holding the handle 70 in a given position relative to the bristle head 20 . For example, in the embodiment depicted in FIG. 3 , eight recesses may be spaced evenly in the floor of the circular channel 73 to form detents that are forty-five degrees apart around the circle. By applying pressure to the handle 70 , the user may force the protrusion out of the recess to allow for rotation of the handle 70 .
[0037] Still other embodiments of the self-cleanable brush 10 do not include a handle 70 . Instead, a user may grasp the bristle head 20 directly when using the brush 10 . In some of these embodiments, a strap or elastic band may be attached across the back-side 15 of the bristle head 20 and the user may slip a hand under the strap or elastic band for added gripping security while using the brush 100 .
[0038] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0039] While the invention has been illustrated and described as embodied in a self-cleanable brush, however, it is not limited to the details shown, since substitutions and changes in the forms and details of the device illustrated and its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. Accordingly, the scope of the present invention is intended to be defined only by reference to the appended claims.
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A self-cleanable hairbrush for use on animals or humans is described that has a frame with strands stretched across it. In one embodiment, the frame is attached to the brush by a pivoting hinge and may be pivoted by the hinge to a position in which the frame is seated flat against a bristle-side of the brush, allowing the strands to slip between the bristles and the frame to be secured in place. As the brush is used, loose hairs, fur, or other debris may become entangled in the bristles. Releasing the frame and allowing it to swing up through the bristles gathers the entangled debris and removes it from bristles, allowing it to be disposed of. The frame and strands may then be re-seated against the bristle-side of the brush, leaving the brush cleaned and ready for re-use.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. Ser. No. 09/237,194, filed Jan. 26, 1999, which is a Continuation of U.S. Pat. No. 5,899,855, issued May 4, 1999, which is a FWC of U.S. Ser. No. 08/233,397, filed Apr. 26, 1994, now abandoned, which is a Continuation of U.S. Pat. No. 5,307,263, issued Apr. 26, 1994. This application is also related to applicant and assignee's co-pending applications listed below: U.S. Pat. No. 5,960,403 (U.S. Ser. No. 09/136,512) which is a Continuation-In-Part of application Ser. No. 08/481,925, filed Jun. 7, 1995, now U.S. Pat. No. 5,899,855, issued on May 4, 1999, which is a FWC of U.S. application Ser. No. 08/233,397 filed on Apr. 26, 1994, now abandoned, which is a Continuation-In-Part of application Ser. No. 07/977,323, filed Nov. 17, 1992, and issued as U.S. Pat. No. 5,307,263. This patent is also a Continuation-In-Part of application Ser. No. 08/666,242, filed Jun. 20, 1996, now abandoned. This application is related to U.S. Pat. No. 6,168,563 (U.S. Ser. No. 09/271,217) which is a Continuation-In-Part of application Ser. No. 08/481,925, filed Jun. 7, 1995, now U.S. Pat. No. 5,899,855, which is a continuation of application Ser. No. 08/233,397, filed Apr. 26, 1994 (now abandoned), which in turn is a Continuation-In-Part of application Ser. No. 07/977,323, filed Nov. 17, 1992 (which has since issued as U.S. Pat. No. 5,307,263); and a Continuation-In-Part of application Ser. No. 08/946,341, filed Oct. 7, 1997, now U.S. Pat. No. 5,997,476, which claims priority from Provisional Application Ser. No. 60/041,746 filed Mar. 28, 1997 and from provisional application Ser. No. 60/041,751 filed Mar. 28, 1997; all of which are incorporated herein by reference. This application is related to U.S. Pat. No. 5,897,493 (U.S. Ser. No. 08/847,009) which also claims priority from Provisional Application Nos. 60/041,751 and 60/041,746 filed Mar. 28, 1997. This application is related to U.S. application Ser. No. 09/658,209 filed on Sep. 8, 2000; U.S. application Ser. No. 10/233,296 filed on Aug. 30, 2002; U.S. application Ser. No. 09/665,242 Mar. 28, 1997; U.S. application Ser. No. 10/319,427 Dec. 12, 2002; and U.S. application Ser. No. 09/713,922 Nov. 15, 2000.
BACKGROUND OF INVENTION
Controlling or curing conditions of ill health generally involves both establishing a therapeutic program and monitoring the progress of the afflicted person. Based on that progress, decisions can be made as to altering therapy to achieve a cure or maintain the affliction or condition at a controlled level. Successfully treating certain health conditions calls for rather frequent monitoring and a relatively high degree of patient participation. For example, in order to establish and maintain a regimen for successful diabetes care, a diabetic should monitor his or her blood glucose level and record that information along with the date and time at which the monitoring took place. Since diet, exercise, and medication all affect blood glucose levels, a diabetic often must record data relating to those items of information along with blood glucose level so that the diabetic may more closely monitor his or her condition and, in addition, can provide information of value to the healthcare provider in determining both progress of the patient and detecting any need to change the patient's therapy program.
Advances in the field of electronics over the past several years have brought about significant changes in medical diagnostic and monitoring equipment, including arrangements for self-care monitoring of various chronic conditions. With respect to the control and monitoring of diabetes, relatively inexpensive and relatively easy-to-use blood glucose monitoring systems have become available that provide reliable information that allows a diabetic and his or her healthcare professional to establish, monitor and adjust a treatment plan (diet, exercise, and medication). More specifically, microprocessor-based blood glucose monitoring systems are being marketed which sense the glucose level of a blood sample that is applied to a reagent-impregnated region of a test strip that is inserted in the glucose monitor. When the monitoring sequence is complete, the blood glucose level is displayed by, for example, a liquid crystal display (LCD) unit.
Typically, currently available self-care blood glucose monitoring units include a calendar/clock circuit and a memory circuit that allows a number of blood glucose test results to be stored along with the date and time at which the monitoring occurred. The stored test results (blood glucose level and associated time and date) can be sequentially recalled for review by the blood glucose monitor user or a health professional by sequentially actuating a push button or other control provided on the monitor. In some commercially available devices, the average of the blood glucose results that are stored in the monitor (or the average of the results for a predetermined period of time, e.g., fourteen days) also is displayed during the recall sequence. Further, some self-care blood glucose monitors allow the user to tag the test result with an “event code” that can be used to organize the test results into categories. For example, a user might use a specific event code to identify test results obtained at particular times of the day, a different event code to identify a blood glucose reading obtained after a period of exercise, two additional event codes to identify blood glucose readings taken during hypoglycemia symptoms and hyperglycemia symptoms, etc. When event codes are provided and used, the event code typically is displayed with each recalled blood glucose test result.
Microprocessor-based blood glucose monitoring systems have advantages other than the capability of obtaining reliable blood glucose test results and storing a number of the results for later recall and review. By using low power microprocessor and memory circuits and powering the units with small, high capacity batteries (e.g., a single alkaline battery), extremely compact and light designs have been achieved that allow taking the blood glucose monitoring system to work, school, or anywhere else the user might go with people encountered by the user not becoming aware of the monitoring system. In addition, most microprocessor-based self-care blood glucose monitoring systems have a memory capacity that allows the system to be programmed by the manufacturer so that the monitor displays a sequence of instructions during any necessary calibration or system tests and during the blood glucose test sequence itself. In addition, the system monitors various system conditions during a blood glucose test (e.g., whether a test strip is properly inserted in the monitor and whether a sufficient amount of blood has been applied to the reagent impregnated portion of the strip) and if an error is detected generates an appropriate display (e.g., “retest”). A data port may be provided that allows test results stored in the memory of the microprocessor-based blood glucose monitoring system to be transferred to a data port (e.g., RS-232 connection) of a personal computer 48 or other such device for subsequent analysis.
Microprocessor-based blood glucose monitoring systems are a significant advance over previously available self-care systems such as those requiring a diabetic to apply a blood sample to reagent activated portions of a test strip; wipe the blood sample from the test strip after a predetermined period of time; and, after a second predetermined period of time, determine blood glucose level by comparing the color of the reagent activated regions of the test strip with a color chart supplied by the test strip manufacturer. Despite what has been achieved, numerous drawbacks and disadvantages still exist. For example, establishing and maintaining diabetic healthcare often requires the diabetic to record additional data pertaining to medication, food intake, and exercise. However, the event codes of currently available microprocessor blood glucose monitoring systems provide only limited capability for tagging and tracking blood glucose test results according to food intake and other relevant factors. For example, the event codes of currently available monitoring systems only allow the user to classify stored blood glucose readings in a manner that indicates blood glucose tests taken immediately after a heavy, light or normal meal. This method of recording information not only requires subjective judgment by the system user, but will not suffice in a situation in which successfully controlling the user's diabetes requires the recording and tracking of relatively accurate information relating to food intake, exercise, or medication (e.g., insulin dosage). An otherwise significant advantage of currently available blood glucose monitoring systems is lost when blood glucose test results must be recorded and tracked with quantitative information relating to medication, food intake, or exercise. Specifically, the system user must record the required information along with a time and date tagged blood glucose test result by, for example, writing the information in a log book.
The use of event codes to establish subcategories of blood glucose test results has an additional disadvantage or drawback. In particular, although alphanumeric display devices are typically used in currently available microprocessor-based blood glucose monitoring systems, the display units are limited to a single line of information having on the order of six characters. Moreover, since the systems include no provision for the user to enter alphanumeric information, any event codes that are used must be indicated on the display in a generic manner, e.g., displayed as “EVENT” etc. This limitation makes the system more difficult to use because the diabetic must either memorize his or her assignment of event codes or maintain a list that defines the event codes. The limited amount of data that can be displayed at any one time presents additional drawbacks and disadvantages. First, instructions and diagnostics that are displayed to the user when calibrating the system and using the system to obtain a blood glucose reading must be displayed a line at a time and in many cases, the information must be displayed in a cryptic manner.
The above-discussed display limitations and other aspects of currently available blood glucose monitoring systems is disadvantageous in yet another way. Little statistical information can be made available to the user. For example, in diabetic healthcare maintenance, changes or fluctuations that occur in blood glucose levels during a day, a week, or longer period can provide valuable information to a diabetic and/or his or her healthcare professional. As previously mentioned, currently available systems do not allow associating blood glucose test results with attendant quantitative information relating to medication, food intake, or other factors such as exercise that affect a person's blood glucose level at any particular point in time. Thus, currently available blood glucose monitoring systems have little or no capability for the generating and display of trend information that may be of significant value to a diabetic or the diabetic's healthcare professional.
Some currently available blood glucose monitoring systems provide a data port that can be interconnected with and transfer data to a personal computer 48 (e.g., via an RS-232 connection). With such a system and a suitable programmed computer, the user can generate and display trend information or other data that may be useful in administering his or her treatment plan. Moreover, in such systems, data also can be transferred from the blood glucose monitoring system to a healthcare professional's computer either directly or remotely by telephone if both the blood glucose monitoring system (or computer) to which the data has been downloaded and the healthcare professional's computer are equipped with modems. Although such a data transfer provision allows a healthcare professional to analyze blood glucose data collected by a diabetic, this aspect of currently available blood glucose monitoring systems has not found widespread application. First, the downloading and subsequent analysis feature can only be used by system users that have ready access to a computer that is programmed with appropriate software and, in addition, have both the knowledge required to use the software (and the inclination to do so). This same problem exists with respect to data transfer to (and subsequent analysis by) a healthcare professional. Moreover, various manufacturers of systems that currently provide a data transfer feature do not use the same data format. Therefore, if a healthcare professional wishes to analyze data supplied by a number of different blood glucose monitoring systems, he or she must possess software for each of the systems and must learn to conduct the desired analyses with each software system.
The above-discussed disadvantages and drawbacks of microprocessor-based self-care health monitoring systems take on even greater significance with respect to children afflicted with diabetes, asthma and other chronic illnesses. In particular, a child's need for medication and other therapy changes as the child grows. Current microprocessor-based self-care health monitoring systems generally do not provide information that is timely and complete enough for a healthcare professional to recognize and avert problems before relatively severe symptoms develop. Too often, a need for a change in medication and/or other changes in therapeutic regimen is not detected until the child's condition worsens to the point that emergency room care is required.
Further, currently available microprocessor-based health monitoring systems have not been designed with children in mind. As previously mentioned, such devices are not configured for sufficient ease of use in situations in which it is desirable or necessary to record and track quantitative information that affects the physical condition of the system user (e.g., medication dosage administered by a diabetic and food intake). Children above the age at which they are generally capable of obtaining blood samples and administering insulin or other medication generally can learn to use at least the basic blood glucose monitoring features of currently available microprocessor-based blood glucose monitoring systems. However, the currently available monitoring systems provide nothing in the way of motivation for a child to use the device and, in addition, include little or nothing that educates the child about his or her condition or treatment progress.
The lack of provision for the entering of alphanumeric data also can be a disadvantage. For example, currently available blood glucose monitoring systems do not allow the user or the healthcare professional to enter information into the system such as medication dosage and other instructions or data that is relevant to the user's self-care health program.
The above-discussed disadvantages and drawbacks of currently available microprocessor-based blood glucose monitoring systems also have been impediments to adopting the basic technology of the system for other healthcare situations in which establishing and maintaining an effective regimen for cure or control is dependent upon (or at least facilitated by) periodically monitoring a condition and recording that condition along with time and date tags and other information necessary or helpful in establishing and maintaining a healthcare program.
SUMMARY OF INVENTION
This invention provides a new and useful system for healthcare maintenance in which the invention either serves as a peripheral device to (or incorporates) a small handheld microprocessor-based unit of the type that includes a display screen, buttons or keys that allow a user to control the operation of the device and a program cartridge or other arrangement that can be inserted in the device to adapt the device to a particular application or function. The invention in effect converts the handheld microprocessor device into a healthcare monitoring system that has significant advantages over systems such as the currently available blood glucose monitoring systems. To perform this conversion, the invention includes a microprocessor-based healthcare data management unit, a program cartridge and a monitoring unit. When inserted in the handheld microprocessor unit 12 , the program cartridge provides the software necessary (program instructions) to program the handheld microprocessor unit 12 for operation with the microprocessor-based data management unit. Signal communication between the data management unit and the handheld microprocessor unit 12 is established by an interface cable. A second interface cable can be used to establish signal communication between the data management unit and the monitoring unit or, alternatively, the monitoring unit can be constructed as a plug-in unit having an electrical connector that mates with a connector mounted within a region that is configured for receiving the monitoring unit.
In operation, the control buttons or keys of the handheld microprocessor-based unit are used to select the operating mode for both the data management unit and the handheld microprocessor-based unit. In response to signals generated by the control buttons or keys, the data management unit generates signals that are coupled to the handheld microprocessor unit 12 and, under control of the program instructions contained in the program cartridge, establish an appropriate screen display on the handheld microprocessor-based unit display. In selecting system operating mode and other operations, the control buttons are used to position a cursor or other indicator in a manner that allows the system user to easily select a desired operating mode or function and provide any other required operator input. In the disclosed detailed embodiment of the invention several modes of operation are made available.
In the currently preferred embodiments of the invention, the handheld microprocessor unit 12 is a compact video game system such as the system manufactured by Nintendo of America Inc. under the trademark “GAME BOY.” Use of a compact video game system has several general advantages, including the widespread availability and low cost of such systems. Further, such systems include switch arrangements that are easily adapted for use in the invention and the display units of such systems are of a size and resolution that can advantageously be employed in the practice of the invention. In addition, such systems allow educational or motivational material to be displayed to the system user, with the material being included in the program cartridge that provides the monitor system software or, alternatively, in a separate program cartridge.
The use of a compact video game system for the handheld microprocessor-based unit of the invention is especially advantageous with respect to children. Specifically, the compact video game systems of the type that can be employed in the practice of the invention are well known and well accepted by children. Such devices are easily operated by a child and most children are well accustomed to using the devices in the context of playing video games. Motivational and educational material relating to the use of the invention can be presented in game-like or animated format to further enhance acceptance and use of the invention by children that require self-care health monitoring.
A microprocessor-based health monitoring system that is configured in accordance with the invention provides additional advantages for both the user and a healthcare professional. In accordance with one aspect of the invention, standardized reports are provided to a physician or other healthcare provider by means of facsimile transmission. To accomplish this, the data management unit of the currently preferred embodiments of the invention include a modem which allows test results and other data stored in system memory to be transmitted to a remote clearinghouse via a telephone connection. Data processing arrangements included in the clearinghouse perform any required additional data processing; format the standardized reports; and, transmit the reports to the facsimile machine of the appropriate healthcare professional.
The clearinghouse also can fill an additional communication need, allowing information such as changes in medication dosage or other information such as modification in the user's monitoring schedule to be electronically sent to a system user. In arrangements that incorporate this particular aspect of the invention, information can be sent to the user via a telephone connection and the data management unit modem when a specific inquiry is initiated by the user, or when the user establishes a telephone connection with the clearinghouse for other purposes such as providing data for standardized reports.
The clearinghouse-facsimile aspect of the invention is important because it allows a healthcare professional to receive timely information about patient condition and progress without requiring a visit by the patient (system user) and without requiring analysis or processing of test data by the healthcare professional. In this regard, the healthcare professional need not possess or even know how to use a computer and/or the software conventionally employed for analysis of blood glucose and other health monitoring data and information.
The invention also includes provision for data analysis and memory storage of information provided by the user and/or the healthcare professional. In particular, the data management units of the currently preferred embodiments of the invention include a data port such as an RS-232 connection that allows the system user or healthcare professional to establish signal communication between the data management unit and a personal computer or other data processing arrangement. Blood glucose test data or other information can then be downloaded for analysis and record keeping purposes. Alternatively, information such as changes in the user's treatment and monitoring regimen can be entered into system memory. Moreover, if desired, remote communication between the data management unit and the healthcare professional's computer can be established using the clearinghouse as an element of the communications link. That is, in the currently preferred arrangements of the invention a healthcare professional has the option of using a personal computer that communicates with the clearinghouse via a modem and telephone line for purposes of transmitting instructions and information to a selected user of the system and/or obtaining user test data and information for subsequent analysis.
The invention can be embodied in forms other than those described above. For example, although small handheld microprocessor units such as a handheld video game system or handheld microprocessor units of the type often referred to as palm computers provide many advantages, there are situations in which other compact micraprocesor units can advantageously be used. The various types of units that can be employed include using compact video game systems of the type that employ a program cartridge, but uses a television set or video monitor instead of a display unit that is integrated into the previously described handheld microprocessor units.
Those skilled in the art also will recognize that the above-described microprocessor-implemented functions and operations can be apportioned between one or more microprocessors in a manner that differs from the above-described arrangement. For example, in some situations, the programmable microprocessor unit and the program cartridge used in practicing the invention may provide memory and signal processing capability that is sufficient for practicing the invention. In such situations, the microprocessor of the microprocessor-based data management unit of the above embodiments in effect is moved into the video game system, palm computer or programmable microprocessor device. In such an arrangement, the data management unit can be realized as a relatively simple interface unit that includes little or no signal processing capability. Depending upon the situation at hand, the interface unit may or may not include a telephone modem and/or an RS connection (or other data port) for interconnecting the healthcare system with a computer or other equipment. In other situations, the functions and operations associated with processing of the monitored healthcare data may be performed by a microprocessor that is added to or already present in the monitoring device that is used to monitor blood glucose or other condition.
Because the invention can be embodied to establish systems having different levels of complexity, the invention satisfies a wide range of self-care health monitoring applications. The arrangements that include a modem (or other signal transmission facility) and sufficient signal processing capability can be employed in situations in which reports are electronically transmitted to a healthcare professional either in hard copy (facsimile) form or in a signal format that can be received by and stored in the healthcare professional's computer. On the other hand, less complex (and, hence, less costly) embodiments of the invention are available for use in which transfer of system information need not be made by means of telephonic data transfer or other remote transmission methods. In these less complex embodiments, transfer of data to a healthcare professional can still be accomplished. Specifically, if the program cartridge includes a battery and suitable program instructions, monitored healthcare data can be stored in the program cartridge during use of the system as a healthcare monitor. The data cartridge can then be provided to the healthcare professional and inserted in a programmable microprocessor unit that is the same as or similar to that which was used in the healthcare monitoring system. The healthcare professional can then review the data, and record it for later use, and/or can use the data in performing various analyses. If desired, the microprocessor unit used by the healthcare professional can be programmed and arranged to allow information to be stored in the cartridge for return to and retrieval by the user of the healthcare monitoring system. The stored information can include messages (e.g., instructions for changes in medication dosage) and/or program instructions for reconfiguring the program included in the cartridge so as to effect changes in the treatment regimen, the analyses or reports to be generated by the healthcare monitoring system, or less important aspects such as graphical presentation presented during the operation of the health care system.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram that illustrates a healthcare monitoring system arranged in accordance with the invention;
FIG. 2 diagrammatically illustrates monitoring systems constructed in accordance with the invention connected in signal communication with a remotely located computing facility which includes provision for making the data supplied by the monitoring system of the invention available to a designated healthcare professional and/or for providing data and instructions to the system user;
FIG. 3 is a block diagram diagrammatically depicting the structural arrangement of the system data management unit and its interconnection with other components of the system shown in FIG. 1 ;
FIGS. 4-10 depict typical system screen displays of data and information that can be provided by the arrangements shown in FIGS. 1-3 ; and
FIG. 11 diagrammatically illustrates an alternative healthcare monitoring system that is arranged in accordance with the invention.
DETAILED DESCRIPTION
FIG. 1 depicts a self-care health monitoring system arranged in accordance with the invention. In the arrangement shown in FIG. 1 a data management unit 10 is electrically interconnected with a handheld microprocessor-based unit 12 via a cable 14 . In the depicted arrangement, data management unit 10 also is electrically interconnected with a blood glucose monitor 16 of the type capable of sensing blood glucose level and producing an electrical signal representative thereof. Although FIG. 1 illustrates blood glucose monitor 16 as being connected to data management unit 10 by a cable 18 it may be preferable to construct blood glucose monitor 16 as a plug-in unit that is placed in a recess or other suitable opening or slot in data management unit 10 . Regardless of the manner in which blood glucose monitor 16 is interconnected with data management unit 10 both that interconnection and cable 14 are configured for serial data communication between the interconnected devices.
Also shown in FIG. 1 are two additional monitoring devices and 22 which are electrically connected for serial data communication with data management unit 10 via cables 24 and 26 respectively. Monitoring units 20 and 22 of FIG. 1 represent devices other than blood glucose monitor 16 that can be used to configure the invention for self-care health monitoring applications other than (or in addition to) diabetes care. For example, as is indicated in FIG. 1 the monitoring device 20 can be a peak-flow meter that provides a digital signal representative of the airflow that results when a person suffering from asthma or another chronic respiratory affliction expels a breath of air through the meter. As is indicated by monitor 22 of FIG. 1 various other devices can be provided for monitoring conditions such as blood pressure, pulse, and body temperature to thereby realize systems for self-care monitoring and control of conditions such as hypertension, certain heart conditions and various other afflictions and physical conditions. Upon understanding the hereinafter discussed aspects and features of the invention it will be recognized that the invention is easily implemented for these and other types of healthcare monitoring. In particular, monitors used in the practice of the invention can be arranged in a variety of ways as long as the data to be recorded or otherwise employed by handheld microprocessor unit 12 and/or data management unit 10 is provided in serial format in synchronization with clock signals provided by data management unit 10 . As is the case with blood glucose monitor 16 the additional monitors can be configured as plug-in units that are directly received by data management unit 10 or can be connected to data management unit 10 with cables (as shown in FIG. 1 ). As is shown in FIG. 1 , handheld microprocessor unit 12 includes a display screen 28 and a plurality of switches or keys ( 30 , 32 , 34 , 36 , and 38 in FIG. 1 ) which are mounted on a housing 40 . Located in the interior of housing 40 but not shown in FIG. 1 are a microprocessor, memory circuits, and circuitry that interfaces switches 30 , 32 , 34 , 36 and 38 with the microprocessor. Stored in the memory of program handheld microprocessor unit 12 is a set of program instructions that establishes a data protocol that allows handheld microprocessor unit 12 to perform digital data signal processing and generate desired data or graphics for display on display unit 28 when a program cartridge 42 is inserted in a slot or other receptacle in housing 40 . That is, program cartridge 42 of FIG. 1 includes read-only memory units (or other memory means such as battery-powered random access memory) which store program instructions and data that adapt handheld microprocessor for operation in a blood glucose monitoring system. More specifically, when the instructions and data of program cartridge 42 are combined with program instructions and data included in the internal memory circuits of handheld microprocessor unit 12 , handheld microprocessor unit 12 is programmed for processing and displaying blood glucose information in the manner described below and additional monitors to provide health monitoring for asthma and various other previously mentioned chronic conditions. In each case, the plurality of switches or keys ( 30 , 32 , 34 , 36 , and 38 in FIG. 1 ) are selectively operated to provide signals that result in pictorial and/or alphanumeric information being displayed by display unit 28 . Various devices are known that meet the above-set forth description of handheld microprocessor unit 12 . For example, compact devices are available in which the plurality of keys allows alphanumeric entry and internal memory is provided for storing information such as names, addresses, phone numbers, and an appointment calendar. Small program cartridge or cards can be inserted in these devices to program the device for various purposes such as the playing of games, spreadsheet application, and foreign language translation sufficient for use in travel. More recently, less compact products that have more extensive computational capability and are generally called “palm top computers” have been introduced into the marketplace. These devices also can include provision for programming the device by means of an insertable program card or cartridge.
The currently preferred embodiments of the invention are configured and arranged to operate in conjunction with yet another type of handheld microprocessor unit 12 . Specifically, in the currently preferred embodiments of the invention, program cartridge 42 is electrically and physically compatible with commercially available compact video game systems, such as the system manufactured by Nintendo of America Inc. under the trademark “GAME BOY.” Configuring data management unit 10 and program cartridge 42 for operation with a handheld video game system has several advantages. For example, the display unit 28 of such a device provides display resolution that allows the invention to display both multi-line alphanumeric information and graphical data. In this regard, the 160×144 pixel dot matrix-type liquid crystal display screen 28 currently used in the above-referenced compact video game systems provides sufficient resolution for at least six lines of alphanumeric text, as well as allowing graphical representation of statistical data such as graphical representation of blood glucose test results for a day, a week, or longer.
Another advantage of realizing handheld microprocessor unit 12 in the form of a compact video game system is the relatively simple, yet versatile arrangement of switches that is provided by such a device. For example, as is indicated in FIG. 1 a compact video game system includes a control pad 30 that allows an object displayed on display unit 28 to be moved in a selected direction (i.e., up-down or left-right). As also is indicated in FIG. 1 compact video game systems typically provide two pair of distinctly-shaped push button switches. In the arrangement shown in FIG. 1 a pair of spaced-apart circular push button switches ( 36 and 38 ) and a pair of elongated switches ( 32 and 34 ) are provided. The functions performed by the two pairs of switches is dependent upon the program instructions contained in each program cartridge 42 . Yet another advantage of utilizing a compact video game system for handheld microprocessor-based unit of FIG. 1 is the widespread popularity and low cost of such units. In this regard, manufacture and sale of a data management unit 10 blood glucose monitor 16 and program cartridge 42 that operate in conjunction with a compact microprocessor-based video allows the self-care health monitoring system of FIG. 1 to be manufactured and sold at a lower cost than could be realized in an arrangement in which handheld unit is designed and manufactured solely for use in the system of FIG. 1 . An even further advantage of using a compact video game system for handheld microprocessor is that such video game systems include means for easily establishing the electrical interconnection provided by cable in FIG. 1 . In particular, such compact video game systems include a connector mounted to the game unit housing ( 40 in FIG. 1 ) and a cable that can be connected between the connectors of two video game units to allow interactive operation of the two interconnected units (i.e., to allow contemporaneous game play by two players or competition between players as they individually play identical but separate games). In the preferred embodiments of the invention, the “two-player” cable supplied with the compact video game unit being used as handheld microprocessor unit 12 is used as cable to establish serial data communication between the handheld microprocessor unit 12 (compact video game system) and data management unit 10 . In these preferred embodiments, the program instructions stored on the memory of data management unit 10 and program cartridge 42 respectively program data management unit 10 and the compact video game system (i.e., handheld microprocessor unit 12 ) for interactive operation in which switches 30 , 32 , 34 , 36 and 38 are used to control the operation of data management unit 10 (e.g., to select a particular operational mode such as performance of a blood glucose test or the display of statistical test data and, in addition, to control operation such as selection of an option during operation of the system in a particular operational mode). In each operational mode, data management unit 10 processes data in accordance with program instructions stored in the memory circuits of data management unit 10 . Depending upon the operational mode selected by the user, data is supplied to data management unit 10 by blood glucose monitor 16 by additional monitors ( 20 and 22 in FIG. 1 ) or any interconnected computers or data processing facility (such as the hereinafter described user's computer 48 and clearinghouse 54 of FIG. 1 ) During such operation, mode switches and are selectively activated so that signals are selectively coupled to the video game system (handheld microprocessor unit 12 and processed in accordance with program instructions stored in program cartridge 42 . The signal processing performed by handheld microprocessor unit 12 results in the display of alphanumeric, symbolic, or graphic information on the video game display screen 28 (i.e., display unit 28 in FIG. 1 which allow the user to control system operation and obtain desired test results and other information.
Although the above-discussed advantages apply to use of the invention by all age groups, employing a compact video game system in the practice of the invention is of special significance in monitoring a child's blood glucose or other health parameters. Children and young adults are familiar with compact video game systems. Thus, children will accept a health monitoring system incorporating a compact video game system more readily than a traditional system, even an embodiment of the invention that uses a different type of handheld microprocessor unit 12 . Moreover, an embodiment of the invention that functions in conjunction with a compact video game system can be arranged to motivate children to monitor themselves more closely than they might otherwise by incorporating game-like features and/or animation in system instruction and test result displays. Similarly, the program instructions can be included in program cartridge 41 , 42 and 43 (or additional cartridges) that allow children to select game-like displays that help educate the child about his or her condition and the need for monitoring.
With continued reference to FIG. 1 data management unit 10 of the currently preferred embodiments of the invention includes a data port 44 that allows communication between data management unit 10 and a personal computer 48 (or other programmable data processor). In the currently preferred embodiments of the invention, data port 44 is an RS-232 connection that allows serial data communication between data management unit 10 and personal computer 48 . In the practice of the invention, personal computer 48 can be used to supplement data management unit 10 by, for example, performing more complex analyses of blood glucose and other data that has been supplied to and stored in the memory circuits of data management unit 10 . With respect to embodiments of the invention configured for use by a child, personal computer 48 can be used by a parent or guardian to review and analyze the child's progress and to produce printed records for subsequent review by a healthcare professional. Alternatively, personal computer 48 can be used to supply data to data management unit 10 that is not conveniently supplied by using handheld microprocessor switches and as an operator interface to the system shown in FIG. 1 . For example, some embodiments of the invention may employ a substantial amount of alphanumeric information that must be entered by the system user. Although it is possible to enter such data by using switches 30 , 32 , 34 , 36 and 38 in conjunction with menus and selection screens displayed on display screen 28 of FIG. 1 it may be more advantageous to use a device such as personal computer 48 for entry of such data. However, if personal computer 48 is used in this manner, some trade-off of system features may be required because data management unit 10 must be temporarily interconnected with personal computer 48 during these operations. That is, some loss of system mobility might result because a suitably programmed personal computer 48 would be needed at each location at which data entry or analysis is to occur.
As is indicated in FIG. 1 data management unit 10 of the currently preferred embodiments of the invention also includes a modem that allows data communication between data management unit 10 and a remote computing facility identified in FIG. 1 as clearinghouse 54 via a conventional telephone line 64 (indicated by reference numeral 50 in FIG. 1 and a modem 52 that interconnects clearinghouse 54 and telephone line 50 . As shall be described in more detail, clearinghouse computing facility 54 facilitates communication between a user of the system shown in FIG. 1 and his or her healthcare professional and can provide additional services such as updating system software. As is indicated by facsimile machine 55 of FIG. 1 , a primary function of clearinghouse 54 is providing the healthcare professional with standardized reports 56 , which indicate both the current condition and condition trends of the system user. Although a single facsimile machine 55 is shown in FIG. 1 it will be recognized that numerous healthcare professionals (and hence facsimile machine 55 can be connected in signal communication with a clearinghouse 54 . Regardless of whether a compact video game system, another type of commercially available handheld microprocessor-based unit, or a specially designed unit is used, the preferred embodiments of FIG. 1 provide a self-care blood glucose monitoring system in which program cartridge 42 (a) handheld microprocessor unit 12 for displaying instructions for performing the blood glucose test sequence and associated calibration and test procedures; (b) handheld microprocessor unit for displaying (graphically or alphanumerically) statistical data such as blood glucose test results taken during a specific period of time (e.g., a day, week, etc.); (c) handheld microprocessor unit 12 for supplying control signals and signals representative of food intake or other useful information to data management unit 10 ; (d) handheld microprocessor unit 12 for simultaneous graphical display of blood glucose levels with information such as food intake; and (e) handheld microprocessor unit 12 for displaying information or instructions from a healthcare professional that are coupled to data management unit 10 from a clearinghouse 54 . The manner in which the arrangement of FIG. 1 implements the above-mentioned functions and others can be better understood with reference to FIGS. 2 and 3 . Referring first to FIG. 1 clearinghouse 54 receives data from a plurality of self-care microprocessor-based healthcare systems of the type shown in FIG. 1 with the individual self-care health monitoring systems being indicated in FIG. 2 by reference numeral. Preferably, the data supplied to clearinghouse 54 by each individual self-care health monitoring system consists of “raw data,” i.e., test results and related data that was stored in memory circuits of data management unit 10 without further processing by data management unit 10 . For example, with respect to the arrangement shown in FIG. 1 blood glucose test results and associated data such as food intake information, medication dosage and other such conditions are transmitted to clearinghouse 54 and stored with a digitally encoded signal that identifies both the source of the information (i.e., the system user or patient) and those having access to the stored information (i.e., the system user's doctor or other healthcare professional).
As shall be recognized upon understanding the manner in which it operates, clearinghouse 54 can be considered to be a central server for the various system users ( 58 in FIG. 2 ) and each healthcare professional 60 . In that regard, clearinghouse 54 includes conventionally arranged and interconnected digital processing equipment (represented in FIG. 2 by digital signal processor 57 ) which receives digitally encoded information from a user 58 or healthcare professional 60 ; processes the information as required; stores the information (processed or unprocessed) in memory if necessary; and, transmits the information to an intended recipient (i.e., user 58 or healthcare professional 60 . In FIG. 2 rectangular outline 60 represents one of numerous remotely located healthcare professionals who can utilize clearinghouse 54 and the arrangement described relative to FIG. 1 in monitoring and controlling patient healthcare programs. Shown within outline 60 is a computer 62 (e.g., personal computer), which is coupled to clearinghouse 54 by means of a modem (not shown in FIG. 2 and a telephone line 64 . Also shown in FIG. 2 is the previously mentioned 55 which is coupled to clearinghouse 54 by means of a second telephone line 68 . Using the interface unit of computer 62 (e.g., a keyboard or pointing device such as a mouse), the healthcare professional can establish data communication between computer 62 and clearinghouse 54 via telephone line. Once data communication is established between computer and clearinghouse 54 , patient information can be obtained from clearinghouse 54 in a manner similar to the manner in which subscribers to various database services access and obtain information. In particular, the healthcare professional can transmit an authorization code to clearinghouse 54 that identifies the healthcare professional as an authorized user of the clearinghouse 54 and, in addition, can transmit a signal representing the patient for which healthcare information is being sought. As is the case with conventional database services and other arrangements, the identifying data is keyed into computer by means of a conventional keyboard (not shown in FIG. 2 ) in response to prompts that are generated at clearinghouse 54 for display by the display unit 28 of computer (not shown in FIG. 2 ). Depending upon the hardware and software arrangement of clearinghouse 54 and selections made by the healthcare professional via computer patient information can be provided to the healthcare professional in different ways. For example, computer 62 can be operated to access data in the form that it is stored in the memory circuits of clearinghouse 54 (i.e., raw data that has not been processed or altered by the computational or data processing arrangements of clearinghouse 54 . Such data can be processed, analyzed, printed and/or displayed by computer using commercially available or custom software. On the other hand, various types of analyses may be performed by clearinghouse 54 with the results of the analyses being transmitted to the remotely located healthcare professional. For example, clearinghouse 54 can process and analyze data in a manner identical to the processing and analysis provided by the self-care monitoring system of FIG. 1 . With respect to such processing and any other analysis and processing provided by clearinghouse 54 results expressed in alphanumeric format can be sent to computer via telephone line 50 and the modem associated with computer with conventional techniques being used for displaying and/or printing the alphanumeric material for subsequent reference.
The arrangement of FIG. 2 also allows the healthcare professional to send messages and/or instructions to each patient via computer telephone line and clearinghouse 54 . In particular, clearinghouse 54 can be programmed to generate a menu that is displayed by computer and allows the healthcare professional to select a mode of operation in which information is to be sent to clearinghouse 54 for subsequent transmission to a user of the system described relative to FIG. 1 . This same menu (or related submenus) can be used by the healthcare professional to select one or more modes of operation of the above-described type in which either unmodified patient data or the results of data that has been analyzed by clearinghouse 54 is provided to the healthcare provider via computer and/or facsimile machine 55 . In the currently contemplated arrangements, operation of the arrangement of FIG. 2 to provide the user of the invention with messages or instructions such as changes in medication or other aspects of the healthcare program is similar to the operation that allows the healthcare professional to access data sent by a patient, i.e., transmitted to clearinghouse 54 by a data management unit 10 of FIG. 1 . The process differs in that the healthcare professional enters the desired message or instruction via the keyboard or other interface unit of computer. Once the data is entered and transmitted to clearinghouse 54 it is stored for subsequent transmission to the user for whom the information or instruction is intended.
With respect to transmitting stored messages or instructions to a user of the invention, at least two techniques are available. The first technique is based upon the manner in which operational modes are selected in the practice of the invention. Specifically, in the currently preferred embodiments of the invention, program instructions that are stored in data management unit 10 and program cartridge 42 cause the system of FIG. 1 to generate menu screens which are displayed by display unit 28 of handheld microprocessor unit 12 . The menu screens allow the system user to select the basic mode in which the system of FIG. 1 is to operate and, in addition, allow the user to select operational subcategories within the selected mode of operation. Various techniques are known to those skilled in the art for displaying and selecting menu items. For example, in the practice of this invention, one or more main menus can be generated and displayed which allow the system user to select operational modes that may include: (a) a monitor mode (e.g., monitoring of blood glucose level); (b) a display mode (e.g., displaying previously obtained blood glucose test results or other relevant information); (c) an input mode (e.g., a mode for entering data such as providing information that relates to the healthcare regimen, medication dosage, food intake, etc.); and (d) a communications mode (for establishing a communication link between data management unit 10 and personal computer 48 of FIG. 1 or between data management unit 10 and a remote computing facility such as clearinghouse 54 of FIG. 2 ). In embodiments of the invention that employ a compact video game system for handheld microprocessor unit 12 the selection of menu screens and the selection of menu screen items preferably is accomplished in substantially the same manner as menu screens and menu items are selected during the playing of a video game. For example, the program instructions stored in data management unit 10 and program cartridge 42 of the arrangement of FIG. 1 can be established so that a predetermined one of the compact video game switches (e.g., switch 32 in FIG. 1 allows the system user to select a desired main menu in the event that multiple main menus are employed. When the desired main menu is displayed, operation by the user of control pad 30 allows a cursor or other indicator that is displayed on the menu to be positioned adjacent to or over the menu item to be selected. Activation of a switch (e.g., switch of the depicted handheld microprocessor unit 12 ) causes the handheld microprocessor unit 12 and/or data management unit 10 to initiate the selected operational mode or, if selection of operational submodes is required, causes handheld microprocessor unit 12 to display a submenu.
In view of the above-described manner in which menus and submenus are selected and displayed, it can be recognized that the arrangement of FIG. 1 can be configured and arranged to display a menu or submenu item that allows the user to obtain and display messages or instructions that have been provided by a healthcare professional and stored in clearinghouse 54 . For example, a submenu that is generated upon selection of the previously mentioned communications mode can include submenu items that allow the user to select various communication modes, including a mode in which serial data communication is established between data management unit 10 and clearinghouse 54 and data management unit 10 transmits a message status request to clearinghouse 54 . When this technique is used, the data processing system of clearinghouse 54 is programmed to search the clearinghouse 54 memory to determine whether a message exists for the user making the request. Any messages stored in memory for that user are then transmitted to the user and processed for display on display unit 28 of handheld microprocessor unit 12 . If no messages exist, clearinghouse 54 transmits a signal that causes display unit 28 to indicate “no messages.” In this arrangement, clearinghouse 54 preferably is programmed to store a signal indicating that a stored message has been transmitted to the intended recipient (user). Storing such a signal allows the healthcare professional to determine that messages sent to clearinghouse 54 for forwarding to a patient have been transmitted to that patient. In addition, the program instructions stored in data management unit 10 of FIG. 1 preferably allow the system user to designate whether received messages and instructions are to be stored in the memory of data management unit 10 for subsequent retrieval or review. In addition, in some instances it may be desirable to program clearinghouse 54 and data management unit 10 so that the healthcare professional can designate (i.e., flag) information such as changes in medication that will be prominently displayed to the user (e.g., accompanied by a blinking indicator) and stored in the memory of data management unit 10 regardless of whether the system user designates the information for storage.
A second technique that can be used for forwarding messages or instructions to a user does not require the system user to select a menu item requesting transmission by clearinghouse 54 of messages that have been stored for forwarding to that user. In particular, clearinghouse 54 can be programmed to operate in a manner that either automatically transmits stored messages for that user when the user operates the system of FIG. 1 to send information to the clearinghouse 54 or programmed to operate in a manner that informs the user that messages are available and allows the user to access the messages when he or she chooses to do so.
Practicing the invention in an environment in which the healthcare professional uses a personal computer in some or all of the above-discussed ways can be very advantageous. On the other hand, the invention also provides healthcare professionals timely information about system users without the need for a computer ( 62 in FIG. 2 ) or any equipment other than a conventional facsimile machine ( 55 in FIGS. 1 and 2 ). Specifically, information provided to clearinghouse 54 by a system user can be sent to a healthcare professional 60 via telephone line 68 and facsimile machine 55 with the information being formatted as a standardized graphic or textual report ( 56 in FIG. 1 ). Formatting a standardized report 56 (i.e., analyzing and processing data supplied by blood glucose monitor 16 or other system monitor or sensor) can be effected either by data management unit 10 or within the clearinghouse 54 facility. Moreover, various standardized reports can be provided (e.g., the textual and graphic displays discussed below relating to FIGS. 6-10 ) Preferably, the signal processing arrangement included in clearinghouse 54 allows each healthcare professional 60 to select which of several standardized reports will be routinely transmitted to the healthcare professionals' facsimile 55 , and, to do so on a patient-by-patient (user-by-user) basis.
FIG. 3 illustrates the manner in which data management unit 10 is arranged and interconnected with other system components for effecting the above-described operational aspects of the invention and additional aspects that are described relative to FIGS. 4-10 . As is symbolically indicated in FIG. 3 handheld microprocessor unit 12 and blood glucose monitor 16 are connected to a dual universal asynchronous receiver transmitter 70 (e.g., by cables 14 and 18 of FIG. 1 respectively). As also is indicated in FIG. 3 when a system user connects a personal computer 48 (or other programmable digital signal processor) to data port 44 , signal communication is established between personal computer 48 and a second dual universal asynchronous receiver transmitter 72 of data management unit 10 . Additionally, dual universal asynchronous receiver transmitter 72 is coupled to modem 46 so that data communication can be established between data management unit 10 and a remote clearinghouse 54 of FIGS. 1 and 2 . Currently preferred embodiments of data management unit 10 include a plurality of signal sensors 74 , with an individual signal sensor being associated with each device that is (or may be) interconnected with data management unit 10 . As previously discussed and as is indicated in FIG. 3 , these devices include handheld microprocessor unit 12 , blood glucose monitor 16 , personal computer 48 , remote computing facility 54 and, in addition, peak-flow meter 20 or other additional monitoring devices. Each signal sensor 74 that is included in data management unit 10 is electrically connected for receiving a signal that will be present when the device with which that particular signal sensor is associated is connected to data management unit 10 and, in addition, is energized (e.g., turned on). For example, in previously mentioned embodiments of the invention in which data port 44 is an RS-232 connection, the signal sensor 74 that is associated with personal computer 48 can be connected to an RS-232 terminal that is supplied power when a personal computer is connected to data port 44 and the personal computer is turned on. In a similar manner, the signal sensor 74 that is associated with clearinghouse 54 can be connected to modem 46 so that the signal sensor 74 receives an electrical signal when modem 46 is interconnected to a remote computing facility (e.g., clearinghouse 54 of FIG. 2 ) via a telephone line 50 . In the arrangement of FIG. 3 , each signal sensor 74 is a low power switch circuit (e.g., a metal-oxide semiconductor field-effect transistor circuit), which automatically energizes data management unit 10 whenever any one (or more) of the devices associated with signal sensors 74 is connected to data management unit 10 and is energized. Thus, as is indicated in FIG. 3 by signal path 76 each signal sensor 74 is interconnected with power supply 78 which supplies operating current to the circuitry of data management unit 10 and typically consists of one or more small batteries (e.g., three AAA alkaline cells).
The microprocessor and other conventional circuitry that enables data management unit 10 to process system signals in accordance with stored program instructions is indicated in FIG. 3 by central processing unit (CPU) 80 . As is indicated in FIG. 3 by interconnection 82 between CPU 80 and battery 78 , CPU 80 receives operating current from power supply 78 with power being provided only when one or more of the signal sensors 74 are activated in the previously described manner. A clock/calendar circuit 84 is connected to CPU 80 (via signal path 86 in FIG. 3 ) to allow time and date tagging of blood glucose tests and other information. Although not specifically shown in FIG. 3 operating power is supplied to clock/calendar 84 at all times.
In operation, CPU 80 receives and sends signals via a data bus (indicated by signal path 88 in FIG. 3 ) which interconnects CPU 80 with dual universal asynchronous receiver transmitters 70 and 72 . The data bus 88 also interconnects CPU 80 with memory circuits which, in the depicted embodiment, include a system read-only memory (ROM) 90 a program random access memory (RAM) 92 and an electronically erasable read-only memory (EEROM) 94 . System ROM 90 stores program instructions and any data required in order to program data management unit 10 so that data management unit 10 and a handheld microprocessor unit 12 that is programmed with a suitable program cartridge 42 provide the previously discussed system operation and, in addition, system operation of the type described relative to FIGS. 4-10 . During operation of the system, program RAM 92 provides memory space that allows CPU 80 to carry out various operations that are required for sequencing and controlling the operation of the system of FIG. 1 . In addition, RAM 92 can provide memory space that allows external programs (e.g., programs provided by clearinghouse 54 to be stored and executed. EEROM 94 allows blood glucose test results and other data information to be stored and preserved until the information is no longer needed (i.e., until purposely erased) by operating the system to provide an appropriate erase signal to EEROM 94 . FIGS. 4-10 illustrate typical screen displays that are generated by the arrangement of the invention described relative to FIGS. 1-3 . Reference will first be made to FIGS. 4 and 5 which exemplify screen displays that are associated with operation of the invention in the blood glucose monitoring mode. Specifically, in the currently preferred embodiments of the invention, blood glucose monitor 16 operates in conjunction with data management unit 10 and handheld microprocessor unit 12 to: (a) a test or calibration sequence in which tests are performed to confirm that the system is operating properly; and, (b) the blood glucose test sequence in which blood glucose meter 16 senses the user's blood glucose level. Suitable calibration procedures for blood glucose monitors are known in the art. For example, blood glucose monitors often are supplied with a “code strip,” that is inserted in the monitor and results in a predetermined value being displayed and stored in memory at the conclusion of the code strip calibration procedure. When such a code strip calibration procedure is used in the practice of the invention, the procedure is selected from one of the system menus. For example, if the system main menu includes a “monitor” menu item, a submenu displaying system calibration options and an option for initiating the blood glucose test may be displayed when the monitor menu item is selected. When a code strip option is available and selected, a sequence of instructions is generated and displayed by display screen 28 of handheld microprocessor unit 12 to prompt the user to insert the code strip and perform all other required operations. At the conclusion of the code strip calibration sequence, display unit 28 of handheld microprocessor unit 12 displays a message indicating whether or not the calibration procedure has been successfully completed. For example, FIG. 4 illustrates a screen display that informs the system user that the calibration procedure was not successful and that the code strip should be inserted again (i.e., the calibration procedure is to be repeated). As is indicated in FIG. 4 display screens that indicate a potential malfunction of the system include a prominent message such as the “Attention” notation included in the screen display of FIG. 4 . As previously indicated, the blood glucose test sequence that is employed in the currently preferred embodiment of the invention is of the type in which a test strip is inserted in a receptacle that is formed in the blood glucose monitor 16 . A drop of the user's blood is then applied to the test strip and a blood glucose sensing sequence is initiated. When the blood glucose sensing sequence is complete, the user's blood glucose level is displayed.
In the practice of the invention, program instructions stored in data management unit 10 (e.g., system ROM 90 of FIG. 3 ) and program instructions stored in program cartridge 42 of handheld microprocessor unit 12 cause the system to display step-by-step monitoring instructions to the system user and, in addition, preferably result in display of diagnostic messages if the test sequence does not proceed in a normal fashion. Although currently available self-contained microprocessor-based blood glucose monitors also display test instruction and diagnostic messages, the invention provides greater message capacity and allows multi-line instructions and diagnostic messages that are displayed in easily understood language rather than cryptic error codes and abbreviated phraseology that is displayed one line or less at a time. For example, as is shown in FIG. 5 the complete results of a blood glucose test (date, time of day, and blood glucose level in milligrams per deciliter) can be concurrently displayed by display screen 28 of handheld microprocessor unit 12 along with an instruction to remove the test strip from blood glucose monitor 16 . As previously mentioned, when the blood glucose test is complete, the time and date tagged blood glucose test result is stored in the memory circuits of data management unit 10 (e.g., stored in EEPROM 94 of FIG. 3 ). The arrangement shown and described relative to FIGS. 1-3 also is advantageous in that data relating to food intake, concurrent medication dosage and other conditions easily can be entered into the system and stored with the time and date tagged blood glucose test result for later review and analysis by the user and/or his or her healthcare professional. Specifically, a menu generated by the system at the beginning or end of the blood glucose monitoring sequence can include items such as “hypoglycemic” and “hyperglycemic,” which can be selected using the switches of handheld microprocessor unit 12 (e.g., operation of control pad 30 and switch 36 in FIG. 1 ) to indicate the user was experiencing hypoglycemic or hyperglycemic symptoms at the time of monitoring blood glucose level. Food intake can be quantitatively entered in terms of “Bread Exchange” units or other suitable terms by, for example, selecting a food intake menu item and using a submenu display and the switches of handheld microprocessor 12 to select and enter the appropriate information. A similar menu item—submenu selection process also can be used to enter medication data such as the type of insulin used at the time of the glucose monitoring sequence and the dosage.
As was previously mentioned, program instructions stored in data management unit 10 and program instructions stored in program cartridge 42 of handheld microprocessor unit 12 enable the system to display statistical and trend information either in a graphic or alphanumeric format. As is the case relative to controlling other operational aspects of the system, menu screens are provided that allow the system user to select the information that is to be displayed. For example, in the previously discussed embodiments in which a system menu includes a “display” menu item, selection of the menu item results in the display of one or more submenus that list available display options. For example, in the currently preferred embodiments, the user can select graphic display of blood glucose test results over a specific period of time, such as one day, or a particular week. Such selection results in displays of the type shown in FIGS. 6 and 7 respectively. When blood glucose test results for a single day are displayed ( FIG. 6 ) the day of the week and date can be displayed along with a graphic representation of changes in blood glucose level between the times at which test results were obtained. In the display of FIG. 6 small icons identify points on the graphic representation that correspond to the blood glucose test results (actual samples). Although not shown in FIG. 6 coordinate values for blood glucose level and time of day can be displayed if desired. When the user chooses to display a weekly trend graph ( FIG. 7 ) the display generated by the system is similar to the display of a daily graph, having the time period displayed in conjunction with a graph that consists of lines interconnecting points that correspond to the blood glucose test results.
The screen display shown in FIG. 8 is representative of statistical data that can be determined by the system of FIG. 1 (using conventional computation techniques) and displayed in alphanumeric format. As previously mentioned, such statistical data and information in various other textual and graphic formats can be provided to a healthcare professional ( 60 in FIG. 2 ) in the form of a standardized report 56 ( FIG. 1 ) that is sent by clearinghouse 54 to facsimile machine 55 . In the exemplary screen display of FIG. 8 statistical data for blood glucose levels over a period of time (e.g., one week) or, alternatively, for a specified number of monitoring tests is provided. In the exemplary display of FIG. 8 , the system (data management unit 10 or clearinghouse 54 also calculates and displays (or prints) the average blood glucose level and the standard deviation. Displayed also is the number of blood glucose test results that were analyzed to obtain the average and the standard deviation; the number of test results under a predetermined level (50 milligrams per deciliter in FIG. 8 ); and the number of blood glucose tests that were conducted while the user was experiencing hypoglycemic symptoms. As previously noted, in the preferred embodiments of the invention, a screen display that is generated during the blood glucose monitoring sequence allows the user to identify the blood sample being tested as one taken while experiencing hyperglycemic or hypoglycemic symptoms and, in addition, allows the user to specify other relevant information such as food intake and medication information.
The currently preferred embodiments of the invention also allow the user to select a display menu item that enables the user to sequentially address, in chronological order, the record of each blood glucose test. As is indicated in FIG. 9 , each record presented to the system user includes the date and time at which the test was conducted, the blood glucose level, and any other information that the user provided. For example, the screen display of FIG. 9 indicates that the user employed handheld microprocessor unit 12 as an interface to enter data indicating use of 12.5 units of regular insulin; 13.2 units of “NPH” insulin; food intake of one bread exchange unit; and pre-meal hypoglycemic symptoms.
Use of data management unit 10 in conjunction with handheld microprocessor unit 12 also allows display (or subsequent generation of a standardized report showing blood glucose test results along with food intake and/or medication information. For example, shown in FIG. 10 is a daily graph in which blood glucose level is displayed in the manner described relative to FIG. 6 . Related food intake and medication dosage is indicated directly below contemporaneous blood glucose levels by vertical bar graphs.
It will be recognized by those skilled in the art that the above-described screen displays and system operation can readily be attained with conventional programming techniques of the type typically used in programming microprocessor arrangements. It also will be recognized by those skilled in the art that various other types of screen displays can be generated and, in addition, that numerous other changes can be made in the embodiments described herein without departing from the scope and the spirit of the invention.
It will also be recognized by those skilled in the art that the invention can be embodied in forms other than the embodiments described relative to FIGS. 1-10 . For example, the invention can employ compact video game systems that are configured differently than the previously discussed handheld video game systems and palm computers. More specifically, as is shown in FIG. 11 , a self-health monitoring system arranged in accordance with the invention can employ a compact video game system of the type that includes one or more controllers 100 that are interconnected to a game console 102 via cable 104 . As is indicated in FIG. 11 game console 102 is connected to a video monitor or television 106 by means of a cable 108 . Although differing in physical configuration, controller 100 , game console 102 , and the television or video monitor 106 collectively function in the same manner as the handheld microprocessor 12 of FIG. 1 . In that regard, a program cartridge 42 is inserted into a receptacle contained in game console 102 with program cartridge 42 including stored program instructions for controlling microprocessor circuitry that is located inside game console 102 . Controller 100 includes a control pad 30 or other device functionally equivalent to control pad 30 of FIG. 1 and switches that functionally correspond to switches 32 - 38 of FIG. 1 . Regardless of whether the invention is embodied with a handheld microprocessor unit 12 ( FIG. 1 ) or an arrangement such as the compact video game system ( FIG. 11 ) in some cases it is both possible and advantageous to apportion the signal processing functions and operations differently than was described relative to FIGS. 1-10 . For example, in some situations, the microprocessor-based unit that is programmed by a card or cartridge (e.g., handheld unit 12 of FIG. 1 or compact video game console of FIG. 11 ) includes memory and signal processing capability that allows the microprocessor to perform all or most of the functions and operations attributed to data management unit 10 of the embodiments discussed relative to FIGS. 1-10 . That is, the digitally encoded signal supplied by blood glucose monitor 16 (or one of the other monitors 20 and 22 of FIG. 1 ) can be directly coupled to the microprocessor included in game console 102 of FIG. 11 or handheld microprocessor 12 of FIG. 1 . In such an arrangement, the data management unit 10 is a relatively simple signal interface (e.g., interface unit of FIG. 11 ) the primary purpose of which is carrying signals between the blood glucose monitor 16 (or other monitor) and the microprocessor of game console 102 ( FIG. 11 ) or handheld unit ( FIG. 1 ). In some situations, the interface unit may consist primarily or entirely of a conventional cable arrangement such as a cable for interconnection between RS-232 data ports or other conventional connection arrangements. On the other hand, as is shown in FIG. 11 signal interface 110 can either internally include or be connected to a modem 52 , which receives and transmits signals via a telephone line 50 in the manner described relative to FIGS. 1 and 2 .
It also should be noted that all or a portion of the functions and operations attributed to data management unit 10 of FIG. 1 can be performed by microprocessor circuitry located in blood glucose monitor 16 (or other monitor that is used with the system). For example, a number of commercially available blood glucose monitors include a clock/calendar circuit of the type described relative to FIG. 3 and, in addition, include microprocessor circuitry for generating visual display signals and signals representative of both current and past values of monitored blood glucose level. Conventional programming and design techniques can be employed to adapt such commercially available units for the performance of the various functions and operations attributed in the above discussion of FIGS. 1-11 to data management unit 10 and/or the microprocessors of handheld unit 12 and compact video console 102 . In arrangements in which the blood glucose monitor 16 (or other system monitor) includes a microprocessor that is programmed to provide signal processing in the above-described manner, the invention can use a signal interface unit 110 of the above-described type. That is, depending upon the amount of signal processing effected by the monitoring unit (e.g., blood glucose monitor 16 ) and the amount of signal processing performed by the microprocessor of video game console 102 (or handheld unit 12 ) the signal interface required ranges from a conventional cable (e.g., interconnection of RS-232 ports) to an arrangement in which signal interface 110 is arranged for signal communication with an internal or external modem (e.g., modem 52 of FIG. 11 ) or an arrangement in which signal interface 110 provides only a portion of the signal processing described relative to FIGS. 1-10 . The invention also is capable of transmitting information to a remote location (e.g., clearinghouse 54 and/or a remotely located healthcare professional) by means other than conventional telephone lines. For example, a modem ( 52 in FIGS. 1 and 11 ) that is configured for use with a cellular telephone system can be employed to transmit the signals provided by the healthcare monitoring system to a remote location via modulated RF transmission. Moreover, the invention can be employed with various digital networks such as recently developed interactive voice, video and data systems such as television systems in which a television and user interface apparatus is interactively coupled to a remote location via coaxial or fiberoptic cable and other transmission media (indicated in FIG. 11 ) by cable 112 which is connected to television or video monitor. In such an arrangement, compact video game controller and the microprocessor of video game console 102 can be programmed to provide the user interface functions required for transmission and reception of signals via the interactive system. Alternatively, the signals provided by video game console 102 (or handheld unit of FIG. 1 ) can be supplied to the user interface of the interactive system (not shown in FIG. 11 ) in a format that is compatible with the interactive system and allows the system user interface to be used to control signal transmission between the healthcare system and a remote facility such as clearinghouse 54 of FIGS. 1 and 2 .
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A networked health-monitoring system configured to collect and process patient health-related data. A plurality of remote patient sites, includes at least one display; a data management unit configured to facilitate collection of patient health-related data; a memory and stored program instructions for generating health-monitoring related information on the display. A central server connects to the data management unit at each patient site to receive patient health-related data collected at the remote patient sites. The system produces reports, including standardized reports, from the received data.
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This is a continuation of application Ser. No. 309,852, filed Nov. 27, 1972, now abandoned.
BACKGROUND OF THE INVENTION
Fabrics as they come from the loom or the knitting machine in their unfinished state are referred to as greige or grey goods. They may contain warp sizing, trash, oils and off-color impurifications called motes. Before they are ready for the customer the fabrics are desized, scoured, bleached, dyed and finished. Approximately eighty per cent of all cotton fabrics are bleached with hydrogen peroxide.
Hydrogen peroxide bleaching solutions are normally quite unstable as they are decomposed by the action of sunlight, metallic impurities and organic matter. To prevent excessive decomposition of hydrogen peroxide it is stored and shipped in glass, aluminum or stainless steel. In the bleaching process for textile fabrics using hydrogen peroxide as the bleaching agent, an alkali such as sodium hydroxide or soda ash is often used along with a stabilizer which throughout the years has been silicate of soda sold as water glass.
The use of water glass as a stabilizer for hydrogen peroxide solutions has presented objectionable processing problems which have been endured by the textile industry. Water glass creates a serious scaling problem on the bleaching equipment which interferes with the flow of the fabric through the bleaching process. Where hard water is encountered the scaling often clogs feed tanks and pipe lines which requires that the equipment be shut down for cleaning. Splashes and spills on the floor leave a heavy white crust which is difficult to remove and creates a walking hazard to the employees.
The water glass is also objectionable with respect to the cloth being bleached. When silicate solids deposit on the goods, a harsh handle or feel results and the absorbency of the goods will be substantially lower in those places where deposits have occurred. This causes serious difficulties in dyeing operations as uneven dyeing takes place.
BRIEF DESCRIPTION OF THE INVENTION
I have now discovered that sodium orthosilicate is a superior alkali for hydrogen peroxide bleaching solutions. In one aspect of my invention textile fabrics, especially cottons and mixtures of cottons and polyesters are bleached with aqueous hydrogen peroxide solutions containing an effective amount of sodium orthosilicate in combination with a stabilizer which provides a stabilizing amount of magnesium ion and alkali metal polyphosphate. The use of sodium orthosilicate overcomes the many difficulties encountered in using the prior art silicate of soda. An effective amount of the sodium orthosilicate is required in the aqueous hydrogen peroxide solution which is at least 1.5 grams per liter. Useful concentrations of sodium orthosilicate in these solutions will be between 1.5 and 7.5 grams per liter.
In addition to the sodium orthosilicate, an effective amount of magnesium-alkali metal polyphosphate stabilizer is required in my peroxide bleaching solutions and bleaching processes. The manner of use and concentrations is described in U.S. Pat. No. 2,838,459. The magnesium ion concentration will be within the range of 0.03 to 2 grams per liter of magnesium and from 0.03 to 10 grams per liter of alkali metal polyphosphate.
In all other respects the hydrogen peroxide bleaching solutions of my invention and the manner of applying them to textile fabrics follows the conditions which have been employed in the industry for many years.
DETAILED DESCRIPTION OF INVENTION
Woven or knit fabrics as they come from the loom or knitting machine are known as grey goods and usually will contain trash, oils, sizing and off-color motes. Before the grey goods are ready for sale they are desized, scoured, bleached, dyed and finished. Bleaching is usually required for proper dyeing and finishing or for whiteness.
Aqueous hydrogen peroxide is used by the textile industry for bleaching because it is efficient, easy to handle and inexpensive. As hydrogen peroxide comes to the mill from the supplier it is usually acidic. In this condition it is of very little value for bleaching. It must be made alkaline to be effective. Caustic soda is most commonly used with soda ash being used for some particular applications. Although effective as a bleach activator, caustic and other strong alkalies cannot be used alone because they cause the hydrogen peroxide to decompose before the necessary bleaching takes place. To compensate for this a stabilizer has to be used. Liquid silicate of soda, or water glass as it is also known, is the standard stabilizer for the industry. Textile grade water glass is 42° Be' which has a density of 1.408. This water glass contains 10.5% Na 2 O and 26.3% silica (SiO 2 ) for a ratio of 1 Na 2 O to 2.5 SiO 2 . The solids content is 36.8% with the remainder being water.
Additional ingredients may be added to the bleach formula which varies widely from plant to plant and from one type of fabric to another. These include phosphates, sequestrants, fluorescent whitening agents and surfactants. A washing operation follows the bleaching to remove the remaining traces of the bleach ingredients.
The cloth is now ready for finishing if it is to remain white or for dyeing if it is to be colored. Finishing includes pre-shrinking, mercerization, or treatment with anti-stat, flame retardant, durable press and soil release chemical agents.
Sodium silicate or water glass in the aqueous peroxide solutions has the following disadvantages. It forms complex salts with calcium and magnesium which coat the surfaces of the bleaching equipment and surrounding areas with a hard to remove film. These coatings on the equipment cause uneven flow of fabric through the processing equipment. The complex silicate salts which are not washed out of the fabrics resist subsequent dyeing. The high sodium silicate concentration which is about 12 grams/liter in peroxide bleaching solutions is difficult to rinse and the silicate remains on the fabric particularly at folds and gives it a harsh hand or feel, and additionally, may reduce the elasticity of knit fabrics. Since only about one third of sodium orthosilicate is required to replace the entire water glass in the peroxide solutions used today, the disadvantages described above are avoided.
The new bleaching solutions of my invention comprise aqueous solutions of hydrogen peroxide containing an effective amount of sodium orthosilicate. The hydrogen peroxide concentration will generally be within the range of 3 to 15 grams per liter (100% basis). The hydrogen peroxide is supplied commercially to the textile mills as 50 per cent by weight peroxide.
The effective amount of sodium orthosilicate is a concentration of at least 1.5 grams per liter. A useful range of sodium orthosilicate is 1.5 to 7.5 grams per liter. Sodium orthosilicate is a granular material containing 67.4% wt. Na 2 O and 32.6% wt. SiO 2 . The ratio of Na 2 O to SiO 2 is 2 to 1. Sodium orthosilicate is available from Pennwalt Corporation under the trademark Penolox.
The alkalinity and pH of the peroxide bleaching solution are adjusted by varying the amount of sodium orthosilicate used within the range of 1.5 to 7.5 grams per liter. The pH follows the amount of orthosilicate used and will generally be within the range of 10 to 11.5.
The bleaching solutions of my invention use the magnesium-polyphosphate stabilizer for peroxide solutions as disclosed in U.S. Pat. No. 2,838,459 and this teaching is incorporated by reference. My peroxide solutions require from 0.03 to 2 grams of magnesium ion per liter and from 1 to 5 times as much alkali metal polyphosphate (as disclosed in the above patent). Suitable sources of magnesium ion are one or more of the anhydrous and hydrated magnesium sulfate, magnesium chloride, magnesium nitrate and magnesium acetate. The polyphosphate may be supplied by one or more of the alkaline salts selected from the group consisting of sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, the alkali metal polyphosphates such as sodium tetraphosphate, sodium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate or the equivalent potassium polyphosphates, sodium orthophosphate, sodium silicate and sodium metaphosphate.
In deciding on a particular peroxide bleaching formulation, the hydrogen peroxide concentration and the sodium orthosilicate concentration will be varied within the limits described above until a satisfactory whitening of the cloth is obtained. The least amount of magnesium-polyphosphate stabilizer is used consistent with a reasonable amount of peroxide decomposition.
In addition to the stabilizer and alkali which are necessary for efficient bleaching with aqueous peroxide solutions, there may be present other chemical additives such as chelating agents, sequestrants, surfactants, optical whiteners and/or other agents.
The cotton or cotton-polyester gray goods are desized, rinsed in water to remove the desizing solution, and then moved into or through the scouring operation. Scouring is accomplished by the use of strong caustic soda solutions at high temperatures. Scouring removes trash, softens motes and emulsifies oils and greases. After scouring, the fabrics are rinsed again with water and are then passed into the bleaching steps.
Bleaching, as well as the other fabric treating steps, may be done batch-wise or continuously. Continuous bleaching is processed in either rope or open-width forms. In the rope form, the fabric is twisted like a rope as it moves through the processing steps. Open-width processing means that the cloth passes along open and under tension. Most fabrics to be dyed are handled open-width.
The cloth to be bleached is passed into or through a saturator where the bleaching solution is picked up by the fabric. The bleaching solution may be supplied from a head tank where the bleaching solutions are prepared. The cloth is in contact with the bleaching solution in the saturator from one to about five seconds in open-width processing and from one or two minutes when in rope form. The temperature in the saturator will normally be at room temperature.
In continuous bleaching hydrogen peroxide solution requires a high temperature and sufficient contact time with the cloth to achieve effective bleaching. This is accomplished in the peroxide steamer. The temperature may vary from 160°F to boiling at 212°F. The lower temperatures are preferred for polyester blends while higher temperatures are preferred for cotton goods. The cloth hold-up in the steamer may vary from 5 minutes to 2 hours. The steamer is usually a J box in continuous bleaching. In batch bleaching kiers or becks are usually used. Temperatures vary from 160° to about 190°F. Bleaching time will vary from 2 to 5 hours. After bleaching, the fabric is rinsed again with water and then it moves on to the dyeing and finishing operations.
The best mode of practicing my invention will be apparent from a consideration of the following examples:
EXAMPLE 1.
Cotton terrycloth toweling was scoured in rope form and then bleached for about 1 hour at a temperature of about 190°F in a J box in alkaline hydrogen peroxide solution. The saturator had the following concentration: hydrogen peroxide 6 grams per liter; sodium orthosilicate 1.6 grams per liter, magnesium ion 0.08 grams per liter supplied as magnesium sulfate heptahydrate and 0.36 grams per liter of sodium hexametaphosphate; a sequestrant -- Dequest 2000 (methylphosphoric acid sodium salt) at 0.17 grams per liter. A satisfactory whiteness of the toweling was obtained with an 85% pick up of bleaching solution in the saturator. About 150,000 pounds of toweling were bleached in this manner.
EXAMPLE 2.
Bleaching of uncut scoured cotton corduroy was carried out in a 7-minute open width duPont J box. Concentrations in the saturator were as follows:
hydrogen peroxide -- 13 to 14 grams per liter (100%)
sodium orthosilicate -- 7.2 grams per liter
magnesium ion -- 0.08 grams per liter supplied as magnesium sulfate heptahydrate
sodium hexametaphosphate -- 0.36 grams per liter
modified diethylene triamine pentaacetic acid chelate -- 2.3 grams per liter
About 78,000 yards of cloth were process in which the whiteness averaged approximately 85% on the Hunter D-40 reflectometer. This was a very good value for subsequent dyeing of the cloth.
EXAMPLE 3.
The bleaching efficiency of peroxide solutions using caustic soda with water glass stabilizer was compared with the bleaching composistions using sodium orthosilicate and magnesium-polyphosphate stabilizer on unbleached and scoured cotton terrycloth toweling. The cloth was immersed in the solutions described in Table 1 for 1 hour at 200°F. In all runs the water to fabric ratio was 5 to 1. The cloth was rinsed by hand, tumble-dried and the whiteness read on a Hunter D-40 reflectometer by noting the blue reflectance. The results show that equivalent whiteness was obtained by using only one-fourth the amount of alkali in the form of orthosilicate.
Table 1______________________________________Hydrogen Peroxide Solutions - (Basis 1 liter) 1 2 3______________________________________Water glass (42° Be') 7.2 -- --(Na.sub.2 O to SiO.sub.2 1 to 2.5)Caustic soda (100%) 1.2 -- --Trisodium phosphate. 12 hydrate 1.2 -- --Sodium orthosilicate -- 2.4 2.4Magnesium -- 0.08 0.04Sodium hexametaphosphate -- 0.36 0.18pH 10.9 10.8 10.9Hydrogen peroxide (100%) 3.3 3.3 3.3Average whiteness 79.7 79.5 80.3______________________________________
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Textile fabrics have been bleached with aqueous solutions of hydrogen peroxide for many years. Since hydrogen peroxide is quite unstable under bleaching conditions, stabilizers have been necessary and silicate of soda, commonly called water glass, is the stabilizer commonly used in the industry. Water glass has a number of disadvantages when used in commercial bleaching of textiles. This invention provides new processes for bleaching textile fabrics with aqueous solutions of hydrogen peroxide containing sodium orthosilicate in combination with a magnesium ion-polyphosphate ion stabilizer and new compositions of matter comprising aqueous solutions of hydrogen peroxide containing an effective amount of sodium orthosilicate and magnesium-polyphosphate stabilizer.
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BACKGROUND OF THE INVENTION
In my prior U.S. Pat. Nos. 3,968,808; 4,026,313; 4,290,244; and 4,437,275 various portable shelters are disclosed. In my U.S. Pat. No. 3,968,808, a generally semi-spherical framework made of elongate struts and hub means is disclosed which is movable between a collapsed, bundled condition in which the struts are closely bunched and in generally parallel relation and an expanded condition of three dimensional form. As disclosed, such structural frameworks are self-supporting by virtue of self-locking action, particularly with relation to the modules thereof. This self-locking action is achieved, within a module, by an asymmetrical disposition of those struts which extend inwardly from the crossed pairs of struts defining the peripheral sides of the module. In addition to this asymmetry to achieve the self-locking action, the necessary and sufficient condition for the capability for collapsing as well as expanding is that the sum of the distances from one of a pair of corresponding hub means along a strut to its pivotal connection with a crossing strut and back along the crossing strut to the other of the hub means is a constant value for all pairs of pivotally crossing or scissored struts connected to each pair of inner and outer hub means.
In the U.S. Pat. No. 3,968,808, domes, cylinders and modules are disclosed and in the dome structures, the framework is based upon a spherical icosahedron as defined by Buckminster Fuller and one face of which is illustrated in FIGS. 25 and 27 of that patent. By causing a zone of sliding connections in the framework, as for example as indicated at 110 in FIG. 1, three forms of maximum, though incomplete, possible triangular packing within an icosahedron face are disclosed in FIGS. 25 and 27. The incomplete triangular packing is self evident in FIG. 25 whereas in FIG. 27, either the crossed pair of struts 344 or the two crossed pairs of struts 340 and 342 are left out in order to attain the expandable/collapsible framework with the aforesaid zone 110 of sliding connections between crossed struts.
In my U.S. Pat. No. 4,026,313, the full triangular packing of each icosahedron face is made possible by providing alternate zones 18 and 20 of sliding and pivoted connections as shown in FIG. 1 of that patent. For a cylindrical framework, the alternate zones are shown at 62 and 64 in FIG. 2. FIGS. 10-12A illustrate rectangular modules of the general type which may be employed in this invention. U.S. Pat. Nos. 4,290,244 and 4,437,275 are divisions of U.S. Pat. No. 4,026,313 and are directed to modules per se and/or to a module or an assembly of modules in the form of a panel thereof, respectively. Modules such as these may be employed in this invention, although as will be pointed out hereinafter, any module format which is capable of expanding to three dimensional form and collapsing into a bundle is usable in this invention.
It will be noted that in all of the dome or cylinder structures as disclosed in the aforesaid patents, although it is possible to achieve full triangulation, it is not possible to achieve pivotal connection between all of the pairs of crossed struts due to the necessity for providing the zone or zones of sliding connections.
In all of the dome or cylinder framework structures of the above prior patents, movement from the collapsed condition to the expanded condition involves expansion of the base of the structure from the bundled condition outwardly toward and finally to the fully expanded position of the base. Conversely, when the structure is collapsed, the base retreats inwardly from the fully expanded position to the bundled condition. Expansion or collapse is effected by pushing upwardly on the center of the structure or pulling downwardly on the center of the structure, respectively.
Thus, expansion and collapse in such frameworks occurs progressively within the framework and, more particularly, either expansion or collapsing commences predominantly at the top interior of the framework and expands outwardly therefrom toward the base of the framework, the base dimension in the expanded condition representing the maximum position to which the base expands or from which it retreats.
In my aforesaid prior patents, as in this invention, the framework is covered with flexible covering material to provide a shelter function.
BRIEF SUMMARY OF THE INVENTION
The invention disclosed herein basically differs from the structures of the patents of the prior art in that the geometry thereof allows the structure a wide latitude of different configurations. That is, structures of this invention may take many and different forms by the use of different patterns of basic module configurations. By "module" as used herein, is meant any form of expandable/collapsible module which is of three dimensional form when expanded and is of bundled form when collapsed, whether module is of the self-locking type or not.
This invention involves a framework comprised of interconnected modules and which is capable of being manipulated between expanded, fully arched form and collapsed, bundled form by the expedient of flattening separate arch-like series or strings of end-connected modules of the framework so that their ends are beyond the positions thereof which support the framework when in expanded, fully arched condition.
This invention is based upon a rhombicuboctrahedron. Such as solid has eighteen square faces and eight equilateral triangle faces, a total of twenty six faces in all. Although the complete solid may be made in accord with this invention, in the preferred arrangement the bottom pyramid consisting of five square faces and four triangular faces is omitted. Of the remaining faces, it is preferred that two different module forms be employed which, as herein termed are transition modules and flat modules. These two modules are arranged in a basic pattern to simulate faces of the rhombicuboctrahedron. The top central region of the basic rhombicuboctrahedron defines a horizontally disposed flat module of square shape which is bounded on all four of its sides by downwardly arching transition modules with two sides of each triangular face being defined between adjacent sides of the bounding transition modules. In the girthwise direction, the vertically disposed faces are defined alternately by flat modules and transition modules, the flat modules being end-connected to lower ends of the bounding transition modules and further transition modules fill in between such flat modules but in rotationally oriented positions so that their ends join the sides of the girthwise extending flat modules. As noted, adjacent sides of the bounding transition modules define two sides of each triangular face and the base of each triangular face is defined by a further transition module. From this basic arrangement the controlled addition of modules permits the basic rhombicuboctrahedron to be dimimensionally increased in three mutually orthogonal directions, i.e., in height, in width and in length.
It should be noted that not all of the modules defining the girthwise faces of the basic rhombicuboctrahedron need be employed. Thus one or modules may be omitted to provide entrance openings, as desired. When varying the dimensions of the basic rhombioctahedron, thus providing another shape, transition module means and square modules are added as necessary and desired.
Thus, in contrast to my prior patents where the domes and cylinders may not be basically varied as to shape, a feature of this invention is that the dimensions of the shelter may be controlled individually. That is, for a dome or cylinder of my prior patents, if the interior height is desired to be increased, the base dimension must also be increased commensurately. With this invention, the height may be increased without increasing the base dimensions; the base dimensions may be increased without increasing the height; and the base dimensions may be increased individually (both width and length).
Another feature of this invention is the formation of a shelter framework assembly of the type generally described above in which the framework is separated or is separable from the base upwardly to the corners of the top central regions. This leads not only to the dimensionally independent feature noted above but also to an entirely different mode of collapsing and expansion.
Stated otherwise, the invention involves a collapsible/expandable framework comprised of interconnected rectangular modules wherein certain modules forming the framework are either separate or are separable from each other to provide ar allow splitting of the expanded framework from the base upwardly therefrom, providing not only the capability for structuring the framework in many different forms but also providing a unique method of movement between the bundled and expanded conditions.
A basic feature of this invention is the capability of structuring the framework in many different forms by the expedient of allowing elongation of the framework in height, length and width, individually or collectively as may be desired.
In accord with the foregoing feature of the invention, two basic forms of module means are involved in this invention, "flat" module means and "transition" module means. By arranging these module means in different patterns relative to each other the aforesaid many different forms of the framework structure are made possible. By "flat" module means as used herein is meant an arrangement in which the side faces and the end faces are of rectangular form in which planes passing through the side faces are parallel and planes passing through the end faces are parallel, with the two sets of planes being perpendicular to each other. By "transition" module means as used herein is meant an arrangement in which the side faces are of trapezoidal form and the end faces are of rectangular form in which planes passing through the side faces are parallel but the planes passing through the end faces are not parallel and, preferably, are perpendicular to each other. It is preferred that all circumscribing struts of transition and flat modules are of the same length, in which case the inner and outer faces of the flat modules are of equal size and are square whereas the inner and outer faces of the transition modules are both rectangular and of the same width but with the inner face being shorter than the outer face. It is also preferred that the circumscribing sides of all modules are formed by crossed, pivotally connected or scissored struts.
The frameworks of this invention may be of a form such that when expanded, the four sides of a top central, horizontally disposed and rectangular region are defined by downwardly arching transition modules. Further transition modules may be employed to join lower corners of adjacent transition modules at each corner of the top central region to define triangular modules thereat, thus completely enclosing the top central region by the downwardly arching transition modules and the triangular modules arching downwardly at the corners of the top central region. In this way, the fully enclosed top central region offers an extremely rigid truss-like structure. Strings or series of modules forming arch portions of the framework, in which each string includes a side-bounding transition module, are completed by at least one flat module joined in end-to-end connection with an associated transition module. These strings of modules form supporting legs for the framework. Regardless of the exact configurations of these arch portions or of the number of strings or series employed, they must either be separate from each other from the base of the framework upwardly to the corners of the top central regions or be capable of such separation.
The arch portions formed by the series or strings of modules are separate or are split from each other from the base of the framework to the corners of the top central region thereof and the framework is usually sufficiently light in weight to allow it to be picked up off the ground by persons grasping the separate or separated arch portions and then "walking" the framework either to expanded or to collapsed condition or, if the framework is very large and therefore heavy, the same procedure may be done be mechanical means. Regardless of whether the operation is commenced from the bundled condition or from the expanded condition, the arches are moved outwardly to positions in which the feet of the arch portions are disposed outwardly beyond their normal positions of support for the expanded framework. If the framework was expanded before the operation began, the entire framework (i.e., all the modules thereof) begin to collapse in generally uniform fashion as the arch portions are moved outwardly. When the requisite outward positions are reached, their attainment will be apparent because the entire framework will commence to exert inward pulling forces on the arch portions and it remains then to move the arches inwardly while the framework substantially uniformly continues to collapse and further diminish the arch-like nature of the framework. During this procedure, the arch-like nature of the expanded framework continues to diminish and it may then be placed on the ground surface, if smooth and of low friction, whereupon the separate arch portions are further pushed inwardly until the bundled condition is reached. Manipulation from the bundled to the expanded condition is essentially the reverse of the above. As the arch portions are moved outwardly, the framework expands substantially uniformly throughout as the arching thereof progresses. When the maximum outward positions are reached, manipulation of the framework is necessary to compel further arching of the framework as the modules move inwardly until the fully arched or expanded condition of the framework is reached.
Dependent upon the particular configuration of framework employed and the particular configuration of modules employed, certain locking functions may be required when the framework has been expanded and, of course, when such a framework is to be collapsed, unlocking is first required.
The framework is covered with attached flexible material to complete the shelter function of the invention and when the framework has been expanded to its functionally operative condition, the flexible material is held taut by the framework. The covering material may function as a means for limiting the expansions of the modules and for lending stability to the structure, thus participating as a portion of the framework structure as a whole rather than merely as a covering. Generally stated, the covering material must be so related to the structure that it does not interfere with the expanding and collapsing functions, i.e., it may be necessary to separate or split the material as by zippers or the like to allow expansion and collapsing.
In order to provide a framework which has maximum strength, it is preferred that each of the framework is circumscribed by pairs of crossed, pivotally connected struts.
In one aspect, this invention relates to a portable shelter framework comprised of a plurality of expanded, three dimensional modules distributed throughout the framework, each module including crossed pairs of elongate struts and pivot means pivotally joining said struts for allowing said modules to be manipulated between expanded, three dimensional form and strut-bundled form. The framework includes the combination of a plurality of series of end-interconnected modules each defining an arch portion of the framework, the modules of each arch being bounded on opposite sides of the arch by crossed, pivotally connected pairs of struts and each portion including at least one transition module which when expanded defines rectilinearly bounded inner and outer face portions of the arch in which the area of the inner face portion is less than that of said outer face portion.
In one aspect of this invention, there is provided the combination of a series of end-interconnected modules defining an arch portion of a portable shelter assembly framework. The framework is formed of elongate struts and is capable of being expanded into arched three dimensional form and collapsed into boundled form in which struts are disposed in closely spaced, generally parallel relation. In the framework, the modules comprising the series of modules include at least one first module which when expanded defines inner and outer face portions of the arch portion which they define which are of the same rectangular shape and at least one second module which when expanded defines inner and outer rectangular face portions of the arch portion which are of shapes different from each other.
One module of the series is vertically disposed to present a supporting lowermost end thereof located in a definite supporting position relative to the fully expanded and arched framework and the modules including crossed, pivotally connected struts and hub means pivotally joining ends of the pairs of struts for allowing collapse and expansion of the assembly by manipulating the one module of the series of modules outwardly beyond the supporting position thereof.
The present invention concerns three dimensional frameworks for portable shelters which involve pairs of crossed, pivotally connected struts and hub means pivotally connecting the struts of adjacent pairs of struts in orthogonally patterned end-to-end relation to define modules so that the framework is movable between a collapsed, bundled condition in which the struts are disposed in generally parallel relation and an expanded condition in which the modules and framework are of three dimensional form. The modules are so arranged that a horizontally disposed top central region of the framework is at least partially bounded by transition modules extending in different directions therefrom and which effect a transition angularly from the horizontal disposition of the top region to vertically disposed modules of the assembly, i.e., through an angle of 90°. These modules are disposed in a series or string of arch form in which adjacent modules share common end-defining pairs of crossed, pivotally connected struts. By this constuction, the framework may be manipulated between the collapsed condition and the expanded condition by flattening the module strings or arches so that their free ends are positioned beyond those positions which they occupy in the expanded condition of the framework, whereupon the framework may either be manipulated into the expanded condition or into the collapsed condition, dependent upon whether the framework is to be collapsed or expanded
There may be one or more transition modules employed to effect the full 90° transition.
In a preferred form of the invention, the bounding sides of all of the modules are formed by pairs of crossed, pivotally connected struts in which all of the struts are of the same length. In this preferred form, two forms of modules are used, those in which the bounding side faces enclose a rectangular volume and those in which planes passing through opposite side faces are parallel but where such side faces are of trapezoidal form and the opposite end faces of which are of rectangular form in which planes passing therethrough include an angle which is either 90° or an integral division thereof if more than one such module is used in a string thereof.
In one form, this invention relates to a portable shelter having a framework which is characterized by being movable in a coordinated fashion between an expanded condition and a collapsed, bundled condition. Crossed, pivotally connected pairs of struts and hub means pivotally joining said pairs of struts in orthogonally patterned end-to-end relation define modules which are movable between a collapsed condition in which the struts are in bundled, generally parallel relation and an expanded condition in which the modules are of three dimensional form. The expanded framework defines a top central portion and a plurality of separate or separable arch portions extending therefrom downwardly in archwise fashion to terminate in supporting leg modules disposed in supporting leg positions in peripherally spaced relation around the base of the framework. Each arch portion comprises at least one string of modules sharing common ends and corresponding hub means with the arches being disposed such that planes passing through the respective opposite sides of the modules of each arch portion intersect planes passing through the opposite sides of the modules of the respective other arch portions. The framework is movable between its expanded and collapsed conditions by moving the supporting leg modules outwardly beyond their supporting leg positions and then back to or through their supporting leg positions. More particularly, in moving the framework from collapsed condition to the expanded condition, the supporting leg modules are moved outwardly from the bundled relation to beyond their supporting leg positions and then back into their supporting leg positions, whereas when moving the framework from expanded to collapsed condition, the supporting leg modules are moved outwardly beyond their supporting leg positions and then back to and past their supporting leg positions into their bundled positions.
Because of the separate arch portions described above, the sequence involved both in collapsing and expanding is wholly different from that which is involved in my prior patents. In my prior patents, the framework is constructed so that its base expands to a maximum dimension. Thus, in order to allow expansion and collapse, there must be at least one girthwise zone of sliding or limited sliding connections at strut pair crossing points in the structure. Thus in my '808 patent, one zone of sliding at strut pair crossings is disclosed whereas in my '313 patent, alternate zones of pivoting and sliding are disclosed. As noted, according to this invention, no sliding zone or zones are required at all and all crossing points of strut pairs may be pivoted without interfering with the collapsing or expanding of the structure. This allows a maximum of strength for the structure when it is expanded.
In order to collapse or to expand, structures, of the present invention are provided with base-to-top region separations between those arch portions which extend in different directions from the top central region. In this fashion, when collapsing the structure, the "legs" of the structure defined by these arch portions are moved outwardly (i.e., the base of the structure is further expanded) to commence the substantially simultaneous collapse of all of the modules, until a maximum expansion of the base has occurred and the "legs" then begin to retreat radially inwardly toward each other until, finally, all of the struts of the assembly have assumed a generally parallel, bundled relation with respect to each other. For expanding the structure, the reverse sequence is followed. In either case, the movements of the legs reaches a maximum beyond the normal expanded positions thereof and, at this point, the entire structure is ready to be manipulated either to expanded or collapsed condition. The girthwise sequence of modules which form the lower parts of the "legs" are perpendicular to the supporting surface for the assembly and are very stable.
Suitable means is employed to hold the framework in expanded condition. This means may be effected by forming modules to be self-supporting in the manner disclosed in any of my prior U.S. Pat. Nos. 3,698,808; 4,026,313; 4,290,244; and 4,437,275, all of which are incorporated herein by reference. Alternatively, locking link means such as disclosed in the Derus Reissue patent Re. 31,164 may be employed, with or without the face links also employed in that patent, the subject matter of which is also incorporated herein by reference. Other and different means for holding the framework in expanded condition may also be employed as, for example, split hub locking as is disclosed in my prior U.S. Pat. No. 4,473,986, the subject matter of which is incorporated herein by reference. Another form of locking which may be used is that as described in the Alphonse et al U.S. Pat. No. 4,479,340, the subject matter of which is also incorporated herein by reference. The hub means preferred in this invention are those of the ring and blade type as disclosed in my prior U.S. Pat. No. 4,280,251 which is also incorporated herein by reference.
A preferred embodiment of this invention is characterized in that each module of the assembly is self-contained in the sense that each is self-supporting in the expanded or erected condition of the assembly. By self-supporting is meant that each module when expanded attains a "locked" configuration by virtue of the asymmetrical geometry of that module. The necessary and sufficient condition for self-supporting of each module is that for each pair of inner and outer hubs around the periphery of the module, the sum of the distances from an inner hub along a strut extending thereform, to the pivoted crossing point with a strut extending from the corresponding outer hub is the same, but that the individual components of the sum are not equal for those struts which extend from these inner and outer hubs toward the center of the module (i.e., the asymmetry condition). This inequality of individual components leads to the condition in which the plane passing through the pivoted crossing points of these centrally extending strut pairs does not lie at the neutral or non-locking position between the planes passing through the inner and outer hubs respectively. This form of module is preferred because, although it adds weight to the framework, each module is inherently stronger and more rigid than otherwise.
Other and further objectives of this invention will be apparent as the following detailed description procceds.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a side elevational view of a shelter framework of an embodiment of the invention;
FIG. 2 is a plan view of the framework of FIG. 1;
FIG. 3 is a vertical section taken along the plane of section line 3--3 in FIG. 2;
FIG. 4 is a schematic view similar to FIG. 3 but showing a simplified form of framework in its maximum base dimension condition;
FIG. 5 is a schematic view similar to FIG. 4 but showing a retreating position of the framework;
FIG. 6 is a perspective view of one of the vertically disposed modules;
FIG. 7 is a top plan view of the module of FIG. 6;
FIG. 8 is a perspective view of a transition module;
FIG. 9 is a side elevational view of the module of FIG. 8;
FIG. 10 is a schematic sequence illustrating a basic rhombicuboctahedron and one sequence of changing the pattern of modules to achieve different forms of frameworks; and
FIG. 11 is a schematic sequence similar to FIG. 10 but illustrating other pattern changes.
DETAILED DESCRIPTION OF THE INVENTION
With reference at this time to FIG. 2 wherein a top plan view of one form of the invention is illustrated, the top, central portion of the expanded framework shown is seen to be of module form circumscribed by crossed, pivotally connected pairs of struts indicated generally at 10, 12, 14 and 16, in which the ends of the pairs of struts are pivotally joined by hub means later identified in detail. In this particular embodiment, these circumscribing pairs of struts are shared in common with the bounding transition modules 18, 20, 22 and 24 which, as seen better in FIG. 1, are end-connected to the vertically disposed modules 26, 28, 30 and 32. As shown in FIG. 1, the crossed pair of struts 14 defining one side of the top central region module and shared in common with the transition module 22 comprise the strut 34 and the strut 36 which are of equal lengths and are pivotally connected at their centers by the pivot pin or rivet 38. The strut 34 is pivoted at one end to the hub means 40 and at its other end to the hub means 42'. The strut 36 is pivoted at one end to the hub means 40' and at its other end to the hub means 42. It will be understood that the hub means are preferred to be of the general ring and blade form described in detail in my prior U.S. Pat. No. 4,280,251 and that by equal length struts is meant that the distance between the ring holes in the blades at opposite ends of a strut is a fixed distance.
Similarly, the two stuts forming the pair 10, i.e., the struts 48 and 50, are pivotally connected at their mid-points by the pivot pin means 49 and are respectively pivotally connected to the hub means 44 and the hub means 46' underlying the hub means 46 (see FIG. 3) and the hub means 46 and the hub means 44' underlying the hub means 44. Likewise, the struts 52 and 54 forming the pair 12 are respectively pivotally connected at their ends to the hub means 42 and 44'. Lastly, the two struts 56 and 58 forming the pair 16 are pivotally connected at their mid-points by the pivot pin means 57 and are respectively pivotally connected at their ends to the hub means 40 and 46' and to the hub means 40' and 46.
For ease of indentification, the convention which will be used herein with respect to the various hub means is that all hub means which are on the outer side of the framework will be identified by respective reference characters whereas their corresponding inner hub means will be identified by corresponding primed reference characters. Thus, with respect to the corners of the various modules in FIGS. 1-3, the eight hub means of the transition module 20 are identified by the reference characters 42, 42'; 44, 44'; 60, 60'; and 62, 62'. The eight hub means associated with the corners of the transition module 18 are the hub means 44, 44'; 46, 46'; 64, 64'; and 66, 66'. Likewise, the eight corners of the transistion module 22 are associated with the hub means 40, 40'; 42, 42'; 68, 68'; and 70, 70'. Finally, the eight coners of the transition module 24 are associated with the hub means 40, 40'; 46, 46'; 72, 72'; and 74, 74'.
In the embodiment illustrated in FIGS. 1-3, the transition modules effect a 90° transition between the horizontally disposed top central region of the framework and their corresponding vertical modules. For this purpose, the opposite pairs of crossed, pivoted struts are asymmetrically disposed with respect ot the pivot pins or rivets pivotally connecting them. This is evident in FIG. 1, for example, wherein it will be seen that for the near pair 80 of crossed struts, the equal length struts 82 and 84 are pivotally connected by the pivot pin 86 such that the length along the portion of the strut 82 from the hub means 42 to the pivot pin 86 is longer than is the distance from the pivot in 86 to the hub means 62'. As is disclosed in my prior U.S. Pat. No. 3,968,808, the necessary and sufficient condition for allowing the framework to collapse into a bundle of generally parallel struts and to be expanded to its three dimensional form is that for each corresponding pair of inner and outer hub means, the sum of the distance along one strut of a pair of crossed, pivotally connected struts from its pivotal connection with an outer hub means to the pivoted connecting point between that pair of stuts plus the distance back along the other strut of the pair from that pivoted connecting point to the pivotal connection of that other strut with its corresponding inner hub is a constant. To illustrate, the sum of the distance along the strut 82 from its pivotal connection with the hub means 42 to the pivot pin 86 plus the distance from the pivot pin 86 back along the strut 84 to its pivotal connection with the hub means 42' is a constant and is equal to the sum of the distance along the strut 36 from its pivotal connection with the hub means 42 to the pivot pin 38 plus the distance from the pivot pin 38 back along the strut 34 to its pivotal connection with the hub means 42', and so forth. It is evident that this rule requires that this sum is equal to the length of a single strut of the pairs of struts circumscribing a module so that all such circumscribing struts are of equal length. Since the modules of the framework share common strut-defined sides, it follows that a single strut length is employed for all struts which circumscribe the modules, whether the module is of the flat type or of the transition type. For the flat modules, each pair of circumscribing struts are pivoted at their mid-points and for the transition modules, the pairs of struts at opposite ends of the module are also pivoted at their mid-points but along the opposite sides of the transition modules, the struts are not pivoted at their mid-points.
Thus, in the particular embodiment illustrated in FIGS. 1-3, the lengths of all struts which form strut pairs circumscribing the various modules is the same. Thus, the module defining the top central region is of square plan view as are all the vertically oriented modules. On the other hand, all of the transition modules have opposite sides of trapezoidal shape and opposite ends which are of rectangular shape, the planes passing through the crossed struts at the opposite ends of the transition modules intersecting at an angle of 90° so as to effect the aforesaid transition from the horizontally disposed top central region to the upper ends of the vertically disposed modules. The planes passing through the opposite sides of the transition modules are parallel as are the planes passing through the opposite sides of the vertically oriented modules. Likewise, the planes passing through the opposite ends of the vertically oriented modules are parallel to each other.
A single transition module 20 of this emobodiment of the invention is illustrated in perspective in FIG. 8 and in elevation in FIG. 9.
Thus, the transition modules are characterized by the fact that their inner face portions are rectangular but of a shape different from the rectangular shape of their outer face portions. In the case of the vertically disposed modules, their inner and their outer face portions are the same rectangular shape and are, moreover, square.
Moreover, each string of modules such as the end-connected modules 32 and 24 forms an arch portion of the framework and each such arch extends from the top central region downwardly, in archwise fashion, from the top central region in a different direction. Thus, from the base of the framework as is defined by those ends or hub means of the vertically disposed molecules which engage the supporting surface G, the framework is split from the base to the peak or top central region. This separation between arches which extend in different directions from the top central region allows the framework to collapse or to expand in the fashion illustrated in FIGS. 4 and 5 as is later described.
Returning now to FIGS. 1-3 to complete the description of the assembly shown therein, the struts 90 and 92 of the pair of crossed, pivotally connected struts defining the far side of the transition module 20 are asymmetrically pivoted by the pivot pin 94 in the fashion previously described for the near side struts 82 and 84. The strut 90 is pivotally associated with the hub means 60 and 44' whereas the strut 92 is pivotaly associated with the hub means 44 and 60'. The remaining end side of the transition moodule 20 is defined by the crossed, pivotally connected pair of struts 96 and 98 which are centrally pivoted together by the pivot pin 100, in the same fashion that the opposite end struts 52 and 54 are centrally pivoted by the pivot pin 55. Thus, for a transition module such as 20, the opposite ends are each defined by a pair of crossed, pivotally connected struts wherein the pivot pin is located at the centers of the struts and the planes passing through such ends intersect at a right angle whereas its opposite sides are each defined by a pair of crossed, pivotally connected struts in which the pivot pin is located asymmetrically along the struts and the planes passing through these sides are parallel. On the other hand, the opposite ends as well as the opposite sides of the other modules such as the module 28 are each defined by a pair of crossed, pivotally connected struts in which the pivot pin is located centrally of the struts and the planes passing through the respective sides as well as the planes passing through the opposite ends are parallel. One such module 28 is illustrated in larger scale in FIGS. 6 and 7.
As shown in FIG. 6, the two struts 96 and 98 defining one end of the transition module 20 are shared with the module 28, as are the several hub means 60, 60' and 62, 62'. One side of the module 28 is defined by the crossed, pivotally connected pair of struts 110 and 112 which, like the struts 96 and 98, are pivotally connected at their centers by the pivot pin 114. The strut 110 is pivotally connected at one end to the hub means 62 and at its opposite end to the hub means 116' whereas the strut 112 is pivotally connected at one end to the hub means 62' and at its other end to the hub means 116. At its bottom end, the module 28 is defeined by the crossed, pivotally connected pair of struts 118 and 120 which are pivotally joined at their centers by the pivot pin 122. The strut 118 is pivotally connected at one end to the hub means 116 and at its opposite end to the hub means 124'. The strut 120 is pivotally connected at one end to the hub means 116' and at its other end to the hub means 124. Lastly, the other vertical side of the module 28 is defined by the pair of crossed, pivotally connected struts 126 and 128 whose centers are connected by the pivot pin 130. The strut 126 is pivotally connected at one end to the hub means 124 and at its opposite end to the hub means 60'. The strut 126 is pivotally connected at one end to the hub means 124 and at its opposite end to the hub means 60'. Thus, all the sides and ends of the module 28 are the same and this holds true for all other modules of this embodiment of the invention except for the transition modules.
Inasmuch as the circumscribing ends/sides of all similar modules are the same, no further description of the sides and ends of the other transition modules 18, 20, 22 and 24 or of the other modules 26, 30 and 32 and the module defined at the top central region by the circumscribing ends of the transition modules will be given. However, it should be noted that the circumscribing struts are woven in a preferred pattern around each module. This weaving is readily seen in FIG. 6. One way of stating the preferred rule is that if a strut such as 112 is placed outside its associated strut 110, then the next successive strut 96 should be placed inside its associated strut and so on. That is, the next successive strut 128 in the sequence of struts 112, 96, 128 and 118 would be outside its associated strut 126 and, lastly, the strut 118 would be inside its associated strut 120. This weaving pattern distributes the bending actions on the struts evenly while assuring that the inner and outer hub means are in spaced registry with each other when the framework is expanded.
Although the means for holding the framework in the expanded condition has not as yet been described for FIGS. 1-3, it is well at this point to describe the cooperation among the components during manipulation of the framework between collapsed and expanded conditions. For this purpose, a simplified form of framework is illustrated in FIGS. 4 and 5, to which reference is now had.
From these Figures it will be seen that the simplified form of the framework is identical with that described in connection with FIGS. 1-3 except that the self-locking central struts for each module (which are to be described later) are not employed. Thus, the flat modules 14, 28 and 32 are readily seen as well as the transition modules 20 and 24. The various hub means and struts described above in FIGS. 1-3 are also illustrated and additional hub means 125 and 125' as well as struts 126 and 127 of the module 32 and the pivot pin means 128 which pivotally connects them at their mid-points and struts 130 and 132 of the module 24 and the pivot pin means 134 which pivotally connects them in offset relation to their mid-points. FIG. 4 illustrates approximately the maximum position of the framework in making the transition either to e expanded condition or to the collapsed condition. The arch portions defined by the modules 28 and 20 and by the modules 24 and 32 are flattened in comparison with their positions in FIGS. 1-3. Furthermore, all of the modules throughout the framework are in partially collapsed condition. Thus, the depth of each module is greater than its depth in the fully expanded condition, as will be readily evicent from comparison between FIGS. 3 and 4. The position of FIG. 4 is attained by moving all of the arch porions outwardly aw previously described. Thus, with reference to FIG. 2, the arch portion defined by the modules 20 and 28 and the arch portion defined by the module 24 and the module 32 are moved away from each other whereas the arch portion defined by the module 18 and the module 26 and the arch portion defined by the module 22 and the module 30 are moved away from each other. This should be done in as uniform and simultaneous fashion as is reasonably possible. When it is done manually, as is feasible when the weight of the framework and its covering is such that no difficulty is had for four persons to lift the entire assembly off the supporting surface, one person is positioned at each of the four arch portions and the respective four modules 28, 30, 32 and 26 are grasped and the assembly lifted. Then the persons involved move their respective modules as aforesaid until the position of FIG. 4 is reached. At this time, all of the modules of the framework are partially collapsed and they will tend to collapse further under the weight of the framework, exerting inward pulling forces which are readily perceived by the persons holding the framework. If, as described at this time, the framework is being moved from expanded condition to collapsed condition, the persons involved merely respond to the inward pulling forces and move their modules inwardly as is indicated in FIG. 5. Finally, the modules are pushed inwardly until the bundled, collapsed condition is reached.
Starting from the collapsed condition, the four persons involved again grasp their respective modules 28, 30, 32 and 26 and after lifting the framework assembly, they move their respective modules outwardly until the FIG. 4 position is reached. Now, in order to manipulate the framework assembly to the expanded condition, it is necessary not only to move the grasped modules inwardly but also to urge the framework assembly simultaneously toward the expanded condition. This may be done in any way which is convenient. Perhaps the easiest way is for four persons each to manipulate the module they are holding towards its expanded condition as such module is being moved inwardly. Other and different techniques may of course be used as, for example, a fifth person could push upwardly on the framework from the interior, etc.
The particular technique employed may depend in large part upon the type of framework involved. For example, if the framework assembly is of the self-locking module type illustrated in FIGS. 1-3, the transition toward the expanded condition from the FIG. 4 condition is more difficult than is the case for the modified form of the framework, without the self-locking modules, of FIGS. 4 and 5. In fact, for the framework type as in FIGS. 4 and 5, very little effort is required to urge the assembly toward the expanded condition as the modules are moved inwardly from the FIG. 4 position.
Once the framework assembly has been moved to the expanded condition, it will self-lock in the expanded condition if the modules, or some of the modules are of the self-locking type. If no self-locking of the framework modules is employed, extraneous locking is normally desirable. However, it should be noted that the flexible covering material as disclosed in my prior patents will aid in holding the framework assembly is expanded condition. That is, in moving the FIG. 4 condition to the expanded condition, the covering material will become taut as the modules reach a maximum of expansion, and it will thus limit the expanded condition of each module. In some cases, this is sufficient to reatain the framework assembly in the expanded condition, bearing in mind also that with the modules 28, 30, 32 and 26 resting in contact with the supporting surface, a substantial degree of stability is derived therefrom.
However, it is also to be noted that extraneous locking means may also be employed as may be necessary and that such extraneous locking means may take any desired form such as is described in my prior U.S. Pat. No. 4,473,986; the Derus U.S. Pat. No. Re. 31,641; the Alphonse et al U.S. Pat. No. 4,479,340 or the like. In fact, any extraneous locking, holding or anchoring means may be employed, as is desired.
For maximum rigidity and strength, however, the preferred configuration resides in the provision of self-locking module configurations and these are easily implemented in accord with the teachings of my prior patents. Thus, referring to FIGS. 6 and 7, each flat module means may employ the central strut structure therein and which will now be described.
Although FIGS. 6 and 7 illustrate the particular flat module 28, it will be understood that any and all flat modules within the framework may take this form. As illustrated, the outer and inner hub means 140 and 140' are provided. The blades at the inner ends of the struts 142, 144, 146 and 148 are pivotally connected with the ring of the hub means 140 (see my prior U.S. Pat. No. 4,280,521) whereas the blades at the inner ends of the struts 150, 152, 154 and 156 are pivotally connected with the ring of the hub means 140'. Likewise, the blades at the outer ends of the struts 142, 144, 146 and 148 are connected pivotally with the rings of the respective hub means 60', 124', 116' and 62'. The set of struts 142, 144, 146 and 148 are of the same length but are longer than the struts of the set 150, 152, 154 and 156. It will be noted that pairs of struts of the two sets are in crossed, pivoted relation, i.e., they constitute scissored pairs of struts. Thus, the pair of struts 142 and 150 is pivotally connected by the pivot means 160; the pair of struts 144 and 152 is pivotally connected by the pivot means 162; the pair of struts 146 and 154 is pivotally connected by the pivot means 164; and the pair of struts 148 and 156 is pivotally connected by the pivot means 166. The lengths of the struts of the two sets are chosen so that two conditions are met. First, the previously described necessary and sufficient condition for movement between the collapsed condition and expanded condition must be followed. That is, for each pair of inner and outer hub means such as the hubs 62 and 62', the distance along the strut 156 from its pivotal connection with the hub means 62 to the pivot point at 166 plus the distance along the strut 148 from the pivot point at 166 back to its pivotal connection with the hub means 62' is the previously described constant which is equal to the length of a circumscribing strut between its end pivotal points. Second, the necessary and sufficient condition for self-locking must be followed. This necessary and sufficient condition is that a plane passing through the pivot means 160, 162, 164 and 166 must be offset from the plane passing through the pivot means 100, 130, 122 and 144. This is evident from FIG. 7. If these two planes are coincidental, i.e., are one and the same plane, a "neutral" condition prevails and no self-locking action is attained. On the other hand, the more the plane passing through the pivot means 160, 162, 164 and 166 is offset from the plane passing through the pivot means 100, 130, 122 and 114 toward the ultimate position in which such plane also passes through the set of hub means such as the hub means 60, 62, 116 and 124, the stronger the self-locking action becomes. Because the forces of self-locking generated become larger as the ultimate position is approached, it is preferred to soften the self-locking action to some degree by choosing the lengths of the struts of the two sets such that the struts 150, 152, 154 and 156 each lie at a small angle (in the order of 3°-7°) to the plane passing through the hub means 60, 62, 124 and 116.
With reference to FIGS. 8 and 9, the same general principles for self-locking as described above for FIGS. 6 and 7 prevails. The central struts in this case are the set of struts 170, 172, 174 and 176 and the set of struts 180, 182, 184 and 186. The central outer and inner hub means are 178 and 178'. The scissored crossing point are at the pivot means 190, 192, 194 and 196. As noted before, the length of each circumscribing strut such as the strut 52 is of the same length as that of all the other circumscribing struts of all other modules, i.e., the length of the strut 52 in FIGS. 8 and 9 is the same as the length of the strut 98 in FIGS. 6 and 7. Similarly, it is the case that the length of each strut such as the strut 154 in FIGS. 6 and 7 is the same as the length of each strut such as the strut strut 184 of FIGS. 8 and 9. Likewise, the length of each strut such as the strut 146 of FIGS. 6 and 7 is the same as the length of each strut such as the strut 174 of FIGS. 8 and 9. Thus, only three different length struts need be used throughout the entire framework assembly, thus greatly simplifying fabrication.
FIGS. 10 and 11 illustrate how different patterns of modules may be employed to achieve an infinite variety of framework configurations with indepence among height, width and length.
In FIG. 10, a basic rhombicuboctahedron is indicated at 200. From the perspective angle of the Figure, only seven faces of the rhombicuboctahedron are seen. However, there are in reality twenty six faces to this body. What is illustrated are the faces which will be termed herein as the top central face 202, the two transition faces 204 and 206, the girthwise faces 208, 210 and 212, and the triangular (equilateral) face 214. Girthwise of the rhombicuboctahedron, there are five more faces in addition to the three faces 208, 210 and 212 illustrated; in the transition region there are two more transition faces in addition to the transition faces 204 and 206 illustrated and three more triangular faces in addition to the triangular face 214 illustrated. The four transition faces plus the four triangular faces and the top central face constitute the top pyramid of the body. On the bottom pyramid which is not seen, there is a bottom central face corresponding to the face 202 and all of the faces corresponding with the top pyramid transition faces and the top pyramid triangular faces, a total of twenty six faces in all, eight girthwise faces, two central region faces, eight transition faces and eight triangular faces. From the form of the invention illustrated in FIGS. 1-3, it will be seen that the expanded module 30 defines the girthwise face 208, the expanded module 28 defines the girthwise face 212, the expanded module 14 defines the top central face 202, the expanded module 22 defines the transition face 204 and the expanded module 20 defines the transition face 206. Further, it will be seen that the expanded module 32 defines the girthwise face opposite the girthwise face 212, the expanded module 26 defines the girthwise face opposite the girthwise face 208, the expanded module 24 defines the transition face opposite the transition face 206 and the exapnded module 18 defines the transition face opposite the transition face 204.
It will also be evident from FIGS. 1-3 that all of four of the girthwise faces corresponding to the girthwise face 210 in FIG. 10 are left open as entrances for the shelter assembly. Similarly, none of the four triangular transition faces corresponding with the triangular transition face 214 of FIG. 10 is defined by any modules in FIGS. 1-3. In addition, the entire bottom pyramid is not used.
At this time, however, it should be noted that other and different configurations than is illustrated in FIGS. 1-3 may be employed for the basic rhombicuboctahedron. Before discussing these possibilities in detail, it should be pointed out that whereas the basic rhombicuboctahedron is a regular solid having eighteen square faces and eight triangular faces, the frameworks of this invention involve modules which define only four girthwise square faces and no transition faces which are either square or of equilateral form. To illustrate, the four modules 26, 28, 30 and 32 all define when expanded four square girthwise faces. However, if the framework also includes a module which corresponds, say, with the girthwise face 210 of FIG. 10, such module will be a transition module such as that illustrated in FIGS. 8 and 9 (i.e., a module such as 20) but which has been rotated 90° as explained in more detail hereinafter. Thus, such a girthwise transition module will define a rectangular girthwise face rather than a square girthwise face as illustrated at 210 in FIG. 10.
The use of such a further girthwise module is indeed desirable because it not only defines a girthwise face which is at an angle to any falt module adjacent to it and which defines another girthwise face, but it also cooperates with other modules in the framework assembly to complete the triangular face at the corresponding corner of the top central face or region. This lends greater rigidity to the framework when expanded. Indeed, when all four girthwise faces such as 210 are employed, an extremely rigid structure is formed because the top central region is bounded and circumscribed completely by transition modules so that in any vertical section, a deep truss-like structure is present.
Thus, one possibility of modifying the basic rhombicuboctahedron from the form illustrated in FIGS. 1-3 is to omit, say, the two girthwise modules 26 and 30 and add four girthwise transition modules. Such a configuration, referring to FIG. 1 at this time, would omit all of the central or self-locking struts 220 as well as the scissored pairs of struts 221, 226 and 228 and the hub means 222 and 224 as well as their corresponding inner hub means as indicated in FIG. 1 but would retain the two pairs of hub means 68, 68' and 70, 70' as well as the scissored pair of struts 219. A transition module such as the module illustrated in FIGS. 8 and 9 could be added as follows. The two hub means 44 and 44' of FIG. 8 would lie adjacent the positions of the hub means 68, 68' of FIG. 1 with the pair of scissored struts 52 and 54 of FIG. 8 extending vertically and the hub means 42 and 42' of FIG. 8 lying adjacent the positions of the removed hub means 222 and its corresponding inner hub means of FIG. 1 with the two struts 82 and 84 of FIG. 8 extending to the hub means 116 and 116' (i.e., the hub means 62, 62' of FIG. 8 become the hub means 116, 116' of FIG. 1) and the hub means 60, 60' of FIG. 8 become the hub means 62, 62' of FIG. 1 and the two struts 96 and 98 of FIG. 8 becoming the struts 110 and 112 of FIG. 1.
Of course, the three remaining transition modules to be added would be similarly arranged in the pattern of modules. It is to be noted that a transition triangular face would be defined at each corner of the top central module or region 14 to provide the complete bounding or circumscribing of this top central region to provide the truss-like relationship previously described. Although not essential, the added transition modules may be manually joined to a corner of an adjacent transition module for increased rigidity. That is, with relation to the added transition module described above, the hub means 44, 44' of FIG. 8 may be manually joined to the hub means 68, 68' of FIG. 1. Since the framework must be separate or separable from the base of the framework upwardly to the top central region, and especially to the corners of the top central region, if manual joining of the hub means is employed, such joining must be removed before the framework is collapsed.
Such joining is especially important in lending rigidity to the framework if the modules are not of the self-locking type and omit the central struts, employing only the circumscribing pairs of struts. With such a configuration, with four added transition modules as above, the manual joining in and of itself is sufficient not only to lock the framework in expanded condition but also lends such increased rigidity thereto as does not require any further locking, especially since the fabric itself lends stability to the structure.
It will be apparent that additional configurations may be made as, for example, by omitting only one of the girthwise modules in FIG. 1.
Returning to FIG. 10, on the right-hand side thereof as indicated by the arrow, an infinite variation of the module patterns may be made. The seven faces illustrated at the left-hand side of FIG. 10 are identified in the right-hand side as well and it will be seen that addition of transition modules may be made in any one or a combination of orthogonal directions from the triangular face 214. Thus, one or more transition modules 204', 206' or 210' may be added independently to increase the length, width or height of the shelter structure. Obviously, when a transition module 206' is added, the area of the top central region is correspondingly increased as noted by the additions 214'. Similarly, as transition modules 204' are added, the area of the top central region is increased as noted by the additions 214". As transition modules 210 are added, as noted by the module 210', corresponding girthwise modules 208' and 212' must be added. Thus, to increase the shelter length, transition modules 206' are added with corresponding increase in the area of the top central region as at 214'. To increase the shelter width, transition modules 204' are added with corresponding increase in the area of the top central region as at 214". Lastly, to increase the height of the structure, transition modules 210' are added with corresponding additions of the girthwise modules 208' and 212'. Therefore, width, height and length may be controlled independently or in concert. Further, girthwise modules including not only the modules 208 and 210 but also the modules 210 may be omitted from the pattern as desired. The top central region need not be filled in with module structures as such addition of structure lends minimal additional rigidity and principally serves only to add weight to the structure, a feature not usually desirable.
FIG. 11 illustrates another possibility for controlling the shape or dimensions of the structure. In this case, however, the central portion of the Figure as indicated by the first arrow illustrates the simultaneous additions of all three transition modules 204, 206 and 210. The original faces 208 and 212 are preserved in this technique, as is the original top central region 202.
As indicated by the second arrow in FIG. 11, a combination of the two techniques of FIG. 10 and the central portion of FIG. 11 yields still another possibility. It will be appreciated that the technique of FIG. 10 tends toward a cubic or rectangular polyhedral form whereas the technique of the central portion of FIG. 11 tend toward an octahedral form and, lastly, the technique of the right-hand side of FIG. 11 tends toward enlargement of the rhombicuboctahedral form.
The covering material made be made of one piece and may include flaps with zipper or similar edge connections means for covering any openings or the like. Preferably, the covering material is attached to the framework at the hub means in the manner disclosed in any one of my prior patents and in order to allow the arch portions of the framework to separate for expansion or collapsing, the covering is also provided for such separation, even though it may be zipped up to effect the proper covering function when the framework is expanded.
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A portable shelter framework is formed by a series of end-interconnected modules, each defining a separate arch portion of the framework extending in different directions relative to each other. Each module is formed of elongate struts capable of being expanded into arched three dimensional form and collapsed into bundled form.
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FIELD OF THE INVENTION
The present invention relates to security devices for ensuring compliance with computer software licenses. Specifically, the invention relates to nestable hardware "keys" which connect end-to-end and attach to an internal or external expansion board or other adapter for mounting an entire chain of such keys.
BACKGROUND OF THE INVENTION
Security devices for protecting computer software are well known in the prior art. One such device, generally known as a "key" or dongle, is provided with some licensed computer software to prevent software piracy. The key is an I/O device which attaches to the parallel port, serial port, or small computer system interface (SCSI) port of a computer and includes a memory circuit with a stored, encrypted algorithm, such as a password or serial number. During initial installation of the protected program, the encrypted password is stored as a boot patch within the computer. The stored password, perhaps a serial number, looks for an associated password during each supported program initialization process to ascertain whether the correct key is attached properly to the computer system. Initialization of the program is disallowed unless the key password is compared and found to be associated with the stored password.
A number of drawbacks and limitations exist while using current "keys". First, keys generally are installed in the first parallel port, LPT 1, which typically is used for installation and operation of printers and other peripherals. Keys frequently interfere with the use of printers by causing the host computer to receive a busy signal when addressing LPT1.
Additionally, keys are a nuisance because they generally are installed externally and extend outward from LPT 1. Such external installation is cumbersome and prevents, for all practical purposes, installation of more than one key at a time. Increased concerns with ensuring compliance with software licensing has lead to the need to install more than one key.
A heretofore unmet need exists for a method and apparatus enabling internal mounting of multiple, nestable keys, or secure external mounting of such keys, without interfering with operation of LPT1 for other operations, particularly printing operations.
SUMMARY OF THE INVENTION WITH OBJECTS
A nestable key and key mounting mechanism includes a key housing defining a multi-contact receptacle on one end thereof in communication with a multi-contact plug on the opposite end thereof to allow daisy chain connection of keys. One or more keys, connected end-to-end, are installed into a guide which attaches to a circuit board adapted to serve as a housing for the key(s) and an external or internal interface with the computer microprocessor using, for example, LPT3. The guide mechanism is one or more non-conductive tubes each having a tensioning device for biasing the position of the nestable keys towards the connection end of the board. A plurality of interconnected or individual non-conductive tubes each surrounding a tensioning device may be used, particularly for internally mounted circuit boards, and the board may be surrounded with a plastic case, or other non-conductive case, for external circuit boards. The specially configured board also serves as an interface between the computer central processing unit (CPU) and the authentication software located within the key.
A general object of the invention is to provide an authentication key which overcomes the drawbacks and limitations of the prior art.
A specific object of the invention is to provide a nestable authentication key and mounting mechanism to enable internal or external installation of one or more keys connected end-to-end.
Another specific object of the invention is to provide a mounting apparatus for keys, including a circuit board configured with one or more tensioning devices, such as compressible springs, for biasing the position of keys towards the end of the circuit board.
Yet another specific object of the invention is to provide an external housing for a circuit board designed to mount one or more authentication keys in a daisy chain arrangement thereon.
A further object of the present invention is to provide a security device which interfaces to a computer system without interfering with print processes or operation of other peripherals.
These and other objects, advantages and features of the present invention will become more apparent upon considering the following detailed description of preferred embodiments, presented in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings
FIG. 1 is an exploded perspective view of an authentication key and mounting mechanism embodying principles of the present invention.
FIG. 2 is a side view of the authentication key and mounting mechanism of FIG. 1 with the top cover removed to show the mounting mechanism.
FIG. 3 is an enlarged side view of area 2 of FIG. 2.
FIG. 4 is an enlarged perspective view of area 2 of FIG. 2 with a break away view of the top cover.
FIG. 5 is an end view of the authentication key mounting mechanism of FIG. 2.
FIG. 6 is a side view of the authentication key shown in FIGS. 1 through 5.
FIGS. 7A and 7B are, respectively, side and end views of another aspect of an authentication key and mounting mechanism.
FIG. 8 is a side view of an authentication key attached to the connector and without the housing shown in FIGS. 7A and 7B.
FIGS. 9A and 9B are, respectively, side and end views of yet another aspect of an authentication key and mounting mechanism.
FIG. 10 is a side view of an authentication key and connector without the housing shown in FIGS. 9A and 9B.
FIG. 11 is a perspective view of another aspect of an authentication key and mounting mechanism showing, in phantom view, a case which may be provided for external use.
DESCRIPTION OF PREFERRED EMBODIMENTS
An adapter housing and authentication key assembly are shown generally in FIGS. 1 and 2 as reference number 20. Referring now to FIGS. 1-6, the assembly 20 defines key mounting apparatus including a circuit board 30, in the example shown an 8 bit COM/LPT edge connector interface board, which also serves as an interface between the computer microprocessor, using an LPT port, and an authentication key. While the LPT port is a preferred interface in at least some embodiments of the invention, in other embodiments any available parallel, serial, or other port may be used, including shared ports. The board 30 enables connection of the authentication key(s) to either the COM port or to the LPT port using cables 19 which connect to LPT jack 22. Alternatively, conventional RS-232 cables may be provided to connect the board 30 to the microprocessor.
The circuit board 30 preferably is modified by providing a generally rectangular cut out area 24 surrounded on both long sides by circuit board mounting walls 26. Mounting holes 29 are provided in the walls 26 for mounting one or more housings 28. The housings 28 are preferably made from plastic, although other non-conductive materials may be used. The housing 28 shown as an example in FIGS. 1-6 defines a unitary top wall 32, paired side walls 34, a bottom wall (not shown), and a front wall 31 defining mounting openings 33. Mounting flanges 35 having apertures 37 therethrough allow the housings 28 to be attached to circuit board mounting walls 26 by placing screws 39 through mounting holes 29.
As best shown in FIGS. 2 and 4, the housing 28 further defines eight, parallel interior guide walls 36 thereby forming four, enclosed guide tubes 38. The guide tubes 38 of the housings 28 form protective receptacles for surrounding one or more authentication keys.
The housing 28 shown in FIGS. 1-6 is presented as an example only and may be modified so that the housing side walls 34 form the two outside guide walls 36 of the four guide tubes 38 thereby reducing the number of interior guide walls 36 to six. Additionally, the housing 28 may be molded so that the guide tubes 38 are four separate tubes interconnected by contiguous bottom walls therebetween.
As best shown in FIG. 1, the front wall 31 of the housing 28 is secured against a back plate 21 the circuit board 30 when the housing 28 is attached to the circuit board 30. The back plate 21 is used to secure the board 30 within an expansion slot of the computer CPU. Mounting openings 23 are provided in the back plate 21 for access therethrough to mating mounting openings 33 in the front wall 31 of the housing 28. A mechanical back stop 40 extends from one guide wall 36 of each of the guide tubes 38 to retain authentication keys within the openings 23, 33 in, respectively, the back plate 21 and the end wall 31.
At least one tensioning device 42, such as a compressible spring, is mounted to the board 30 by inserting the tensioning device 42 into a guide tube 38. Four springs 42, one in each guide tube, are shown as the tensioning devices in FIGS. 2-5. A conventional female phone connector jack 44, which is electrically connected to circuit board 30, is positioned at the end of each spring 42. The connector jacks 44 may or may not be attached to the end of the springs 42.
One end of an authentication key 50 is attached to each female phone connector jack 44. Compression of the springs 42 allows additional keys 50 to be mounted to the board 30 by connecting the keys 50 end-to-end and inserting the connected keys 50 within guide tubes 38 of the housing 28. The guide tubes 38 of the housing 28, together with the resistance provided by the tensioning device 42, maintains alignment of the connected jacks 44 and the keys 50 as the spring 42 biases the key 50 towards the end of the board 30.
Each key 50 defines a male connector end 52 and a female connector end 54 to enable interconnection of keys 50 in a daisy chain arrangement. The male connector end 52 of the first key 50, inserted within a guide tube 38 for attachment to the board 30, attaches to the female phone connector jack 44. A second key is connected to the first key 50 by inserting the male connector 52 of the second key into the female connector end 54 of the first key. The connectors 54 may be, for example, four pin, six pin, or eight pin phone connectors. The keys 50 further define a housing 56 for a conventional authentication chipset 60. Connectors 52 are operatively connected to connectors 54 in a pass through arrangement.
A second aspect of the present invention is shown in FIGS. 7A, 7B and 8 as reference number 200. FIG. 7A shows an authentication key assembly 200 utilizing for a key mounting apparatus a conventional 8-bit bus RS-232 expansion board 300 which may add an LPT port, or may be used in place of an LPT port, and occupies a single expansion slot in a CPU. An RS-232 jack 220 is provided for cables 330 from the jack 220 to the motherboard of the microprocessor.
The authentication key assembly 200 includes a generally rectangular, plastic guide tube 380 housing a spring 420 to which is attached a DB-9 or DB-25 female connector 440 defining a cable end having a 9 or 25 pin female D-shell. The female connector 440 is electrically connected by cables 330 to the RS-232 jack 220. The female connector 440 defines a key connecting end 442 having a pair of flanges 444 which extend from and are wider than the width of the upper portion of the plastic guide tube 380. One or more external, conventional keys 500, as described above for interfacing with an LPT port, may be attached end-to-end with the first key 500 connected to connector 440. The key(s) 500 are tensioned by the spring 420 and held in position on the board 300 within the guide tube 380 by a back stop 400 at a single opening 446 through back plate 210. The plastic guide tube 380 defines a lower, outer portion 280 extending from and integral with the upper portion of the guide tube 380. The outer portion 280 is shaped to define a channel, or tensioner guide 460, to align the key(s)500 during insertion to secure the key(s) 500 within the channel 460 which serves as a lock support track. Up to four keys 500 may be installed on the board 300 in this aspect of the invention.
A third aspect of the present invention is shown in FIGS. 9A, 9B, and 10, utilizing, as in the FIG. 7A embodiment, a conventional 8-bit RS-232 LPT expansion board 300 for mounting one or more conventional DB-9 authentication keys 5000. A DB-9 RS-232 female connector 440 is provided at the end of each of three springs 420, and each connector 440 is connected by RS-232 cables 330 to an RS-232 jack 220. The back plate 210 and back stops 400 are provided as described above. The DB-9 key(s) 5000 define a male connector end 520 and a female connector end 540 for connection to, respectively, the female connector 440 and another key 5000 or other computer peripheral.
FIG. 11 depicts a fourth aspect of the present invention particularly suitable as an external authentication key assembly for portable computers and for Apple computers, although it will be recognized by those skilled in the art that the assembly also can be mounted internally. A plastic case 600 encloses a housing 28, such as the housings in FIGS. 1 or 7A, mounted to circuit board 620 having a 9-pin end connector 640 and a 25-pin end connector 660. An RS-232 jack, or a SCSI port 680 is provided as an interface between LPT, RS-232, or SCSI cables. A locking plate cover 780 is also provided at the end of the encased assembly to enable secure external use. The encased assembly may be attached to a portable computer by a strip of Velcro or the like (not shown), or it may be secured in support blocks 800.
It will be recognized by those skilled in the art that other standard bus interface connectors may be used on the circuit boards used to mount the authentication keys shown above. For instance, other interface connectors such as EISA (extended industry standard architecture 32-bit), Micro Channel 32-bit, ISA, SPARC, NeXt, or Apple NuBus connectors may be on the selected circuit board. Additionally, the circuit board may be single or double sided and may have card edge connectors, a pin connector (for example, 8 or 16 pins) or a mating male connector at the rear most short side of the board.
While this invention has been described in connection with preferred embodiments thereof, given the teachings herein, modifications and changes may be made by those skilled in the art to which it pertains without departing from the spirit and scope of the invention. For instance, the compression springs shown are an example only and any type of device applying appropriate pressure may be used to bias the authentication keys. Accordingly, the aspects discussed herein are for illustration only and should not limit the scope of the invention herein which is defined by the claims.
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Nestable software license authentication keys connect end-to-end on a circuit board to form an authentication key assembly for internal computer installation or for use as an external assembly connecting to a host system. The circuit board includes at least one plastic housing for one or more authentication keys which define a male connector at one end and a female connector at the opposite end, which connect to a female phone jack(s) electrically connected to the circuit board and attached to the end of a compression spring mounted within each housing. The spring(s) compresses as additional keys are connected end-to-end on the board and the spring biases the keys against the end of the circuit board. The authentication key assemblies may utilize a variety of circuit boards with a variety of connectors, and the external assembly is encased in the plastic housing for use with portable and Apple-type computers.
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BACKGROUND OF THE INVENTION
The present invention relates to a false twist crimping machine of the type disclosed in U.S. Pat. Nos. 4,809,494, 3,962,829 and Re. No. 30,159.
False twist crimping machines serve to crimp endless thermoplastic filament yarns. Such filament yarns are initially spun as flat yarns, and in the false twist crimping machine, a plurality of yarns are processed in side by side parallel working stations. More particularly, each yarn is initially withdrawn from its supply package by a first feed system, then heated in a heater to about 220° C., subsequently cooled, and then advanced through a false twist unit. A second feed system withdraws the yarn from the false twist unit.
The above described false twist method results in a permanent crimp being imparted to the yarn. Crimp values (in accordance with DIN [German Industrial Standards] 53840) amount to 40-50%. However, in many applications, attempts are made to reduce this final crimp behavior substantially. To this end, a secondary heating tube is used at each processing station. This heating tube is arranged between the second and a third feed system, and in the known false twist crimping machine, each tube externally heated. For heating, a heated vapor is preferably used, which achieves a uniformity of heating among the stations.
The effect of the heating tube is dependent on the method parameters of the heating zone. Decisive parameters are in particular the speed of the third feed system, the temperature of the heating tube, as well as its length. A certain deceleration of the yarn speed is generally provided by the third feed system, so as to reduce the yarn tension in the secondary heating tube. However, this deceleration, i.e. the speed difference between the second feed system and third feed system should not become too great, inasmuch as the yarn will slacken and result in yarn breakage. Furthermore, the threadline will become unstable, which leads to so-called voids, i.e. unevennesses of the yarn which later becomes visible in the fabric formed from the yarn.
It is accordingly an object of the present invention to improve and intensify the heating effect of the secondary heating tube of a yarn false twist crimping machine, by a novel design and construction of the heating tube.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are achieved in the embodiments illustrated herein by the provision of a yarn false twist crimping machine which comprises means for advancing a yarn along a path of travel, and false twist crimping means disposed along the path of travel and including means for serially heating, cooling, and false twisting the advancing yarn. Heat setting means is disposed along the path of travel downstream of the false twist crimping means, which comprises a heating tube and a non-heated transport tube fixed to the downstream end of said heating tube. The transport tube has an inside diameter which closely corresponds in size to the inside diameter of the heating tube, and such that the advancing yarn passes serially through the heating tube and the transport tube.
In a preferred embodiment, the machine includes a central frame, and a side frame which is laterally spaced from the central frame so as to define a service aisle therebetween. The false twisting means of each station is mounted on the central frame, and the heating tube is also mounted on the central frame in a generally upright orientation. Also, the non-heated transport tube extends in a generally horizontal direction laterally across the service aisle adjacent the floor and to the side frame, and yarn winding means is mounted on the side frame for receiving the advancing yarn from the transport tube and winding the same into a package.
The present invention has the advantage that in comparison with currently known heater designs, it is possible to operate with a considerably increased deceleration. Furthermore, with the same heating effect, it is possible to reduce the temperatures substantially, which results in a protective treatment of the yarn and savings of energy. A heater temperature of about 180° allows crimping values (for example, 12%) to be reached, which can be reached in conventional heaters only with temperatures of more than 200°.
In accordance with the present invention, the actual heating tube may be constructed of a considerably shorter length than in the past. A substantially sealed, preferably seamless connection is provided with the transport tube, which is not externally heated and which, as experience shows, need not be even insulated, and allows a heat compensation to occur within the entire cross section of the yarn, which replaces by sections the conventional, active heating of the yarn. The connection of the transport tube, which is here described as sealing or seamless, does not mean that the two tubes merge into one another without discontinuity, but that access of air is absent at the transition from one tube to the other.
The very great length of the heating tube including the transport tube necessitate an operator-friendly construction. This problem is solved by the provision of a central frame and a laterally separated side frame, in the manner described above.
It is important that too high of a yarn tension build up be avoided in the transport tube or at the connector between the heating tube and the transport tube, at which the yarn path is turned from a substantially vertical to a substantially horizontal direction. This is accomplished with the features of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when taken in conjunction with the accompanying drawings, in which
FIG. 1 is a cross sectional schematic view of a false twist machine designed and constructed in accordance with the invention;
FIG. 2 is a cross sectional schematic view of a false twist machine of the present invention, and illustrating a first embodiment of a device for threading the yarn into the heating and transport tubes; and
FIG. 3 is a cross sectional schematic view of a false twist crimping machine of the present invention, and illustrating a different embodiment for threading a yarn through the heating and transport tubes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the drawings, a false twist crimping machine is schematically illustrated in FIG. 1, which embodies the present invention. The machine comprises a creel (not shown) which supports a feed yarn package 10, on which a thermoplastic filament yarn 12 is wound. The yarn 12 is withdrawn via deflecting rolls 14 under a certain tension by a feed system 18. In the direction of the advancing yarn, downstream of feed system 18, a first, elongate heater 20 is arranged, through which the yarn 12 advances, and in so doing is heated to a certain temperature. Subsequent to heater 20, a further deflecting yarn guide 22 is positioned, which deflects the yarn and advances it to a cooling plate 24. Heater 20 and cooling plate 24 may be oriented relative to one another approximately in the fashion of a roof, with deflection yarn guide 22 forming the apex of the rooflike structure. Located downstream of cooling plate 24 is a schematically illustrated false twist unit 28. The latter may be designed and constructed in accordance with DE-PS 22 13 881 or U.S. Pat. No. 4,339,915. Subsequent to false twist unit 28, a further feed system 30 is positioned, which serves to draw yarn 12 both over heater 20 and cooling plate 24.
In direction of ,the advancing yarn, downstream of feed system 30, a heating tube 34 is positioned, which is constructed preferably as a curved, tubular member which is surrounded by a heating jacket 32. The heating tube 34 may alternatively be constructed as a linear tube. The heating jacket 32 serves to heat the tube 34 from its outside with vapor at a certain elevated temperature. Adapted to the spatial conditions of the false twist crimping machine, the heating tube 34 and its jacket 32 are preferably arranged in an upright orientation.
Seamlessly connected to the downstream or lower end of the heating tube 34, i.e. substantially sealed against air, is a transport tube 42. This allows for the yarn 12 to transport the atmosphere of heating tube 34 into transport tube 42. A connecting member 38 is provided to interconnect the downstream end of the heating tube 34 to the upstream end of the transport tube 42, and at the right angled elbow in the member there is provided a yarn guide 44 which is constructed as a pin or roll which has a circumferential groove. The groove serves to guide the yarn 12 with the least possible friction from heating tube 34 into the transport tube 42. Surprisingly, it has been found that the heated air entrained by yarn 12 from the heating tube 34 leads to a further reduction of the crimp imparted to yarn 12 in false twist zone 28, despite the relatively low temperature of the heating tube 34, for example, approximately 160° to 180° C., than has been possible with known heating tubes.
At the outlet end of the transport tube 42, a further yarn feed system 46 is positioned. The latter may be followed by a device (not shown) for applying a finish to the yarn 12. The yarn is then wound into a takeup package 50, which is driven on its circumference by a friction roll 52. Arranged upstream of friction roll 52 is a traversing system 54, by which yarn 12 is reciprocated along package 50 and taken up so as to form a cross wind.
Higher temperatures make it possible to obtain lower crimps, for example 12%, which otherwise can be obtained only with heating tubes of a greater length. This results in a better utilization of heat and savings of energy.
It should also be noted that an insulation of the transport tube 42 has been found to be unnecessary, and often not even desirable, so as to bring the yarn at the end of the tube to a temperature below 100° C.
Arranged above the transport tube 42 is a platform 56 which is supported by rails or posts 58 on the floor 60, and which serves as an operator walkway.
In a preferred embodiment, the machine of the present invention comprises a central frame, shown schematically at 64 in FIG. 1, which mounts the false twist device 28, the feed rolls 30 and the upright heating tube 34 and its jacket 32. A side frame, shown schematically at 65, is also provided which is laterally spaced from the central frame so as to define a service aisle therebetween. The side frame 65 supports the package take-up system 52, 54, and it is positioned between the creel (not shown) for the package 10 and the service aisle at 56. As will be seen from the drawings, the heater 20 and the cooling plate 24 are positioned above the service aisle.
The false twist crimping machine shown in FIGS. 2 and 3 corresponds entirely to the machine of FIG. 1, the description of which is herewith referred to. The machine of FIG. 2, however, differs from that of FIG. 1, in that at the outlet end of transport tube 42 a mouthpiece or outlet end 47 is provided in the form of a funnel-shaped widening of the tube. If the need arises, a suction nozzle or orifice 48 of a suction gun 62 which is connected via conventional hoses with a source of vacuum, may be applied to this mouthpiece 47, so as to pull a yarn through heating tube 34 and transport tube 42, as is common practice at the beginning of a new winding operation. To this end, the end of yarn 12 advancing from feed yarn package 10 is pulled in a simple step to the inlet end of heating tube 34 and then pulled with suction gun 62 through both tubes 34 and 42. Thereafter, the yarn 12 advances via the feed system 46 to the traversing system 54 and then to takeup package 50.
The machine of FIG. 3 differs from that of FIG. 2 in that it is provided with a different yarn threading device. In this embodiment, the latter is a device operated by overpressure. To this end, a source of compressed air 36 is connected to a duct 38 via a tube 40. The tube 40 is provided with a valve 37, and extends behind the junction of the heating tube and the transport tube. Upon opening the valve 37, a surge of compressed air flows via duct 38 through the transport tube 42, which produces in heating tube 34 a suction effect. The latter allows the yarn 12 to be drawn or blow through the heating and transport tubes, when the yarn is held in front of the inlet end of heating tube 34.
The heating tube 34 generally corresponds in its dimensions with respect to diameter and length to the dimensions of transport tube 42. The transport tube 42 is unheated, but is heated to a certain degree by the hot air entrained from the heating tube 34 by the advancing yarn 12. However, the influence of the heat decreases continuously from the inlet end to the outlet end of transport tube 42, which is possibly contributory to the unexpectedly advantageous effect provided by the transport tube.
In a preferred embodiment, the dimensions of heating tube and transport tube are identical, except that the heating tube 34 is curved, for example, by a radius ranging from 4 to 10 meters. This curvature causes the advancing yarn to engage the inside portion of the bore of the heating tube, as seen in the drawings. The transport tube is substantially linear. The length of each tube is between 1 meter and 1.5 meters, and the inside diameter of each tube is between 3 and 12 millimeters.
As one specific example, the heating tube 34 measured 1300 mm long and had an inside diameter of 4 mm. The transport tube 42 measured 1300 mm long and had an inside diameter of 4 mm.
In the drawings and specifications, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A false twist crimping machine has a secondary heater positioned downstream of the false twist zone, which comprises a slightly curved, upright, externally heated tube. The upright heating tube has a downstream end which connects with a horizontally directed transport tube which extends laterally across the service aisle of the machine adjacent the floor, and to a side frame which mounts the package take-up system. The inside diameter and length of the transport tube closely correspond to the inside diameter and length of the heating tube.
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BACKGROUND OF THE INVENTION
This invention relates to insoluble anodes for producing electrolytic manganese dioxide.
Electrolytic manganese dioxide is used chiefly as the active material of dry cells or batteries. This manganese dioxide is usually manufactured by electrolysis from an aqueous sulfuric acid-manganese sulfate solution containing from 0.5 to 1.0 mole manganese sulfate and from 0.2 to 0.6 mole free sulfuric acid per liter of the solution.
The aqueous solution upon electrolysis with a direct current on the order of 0.8 A/cm 2 deposits manganese dioxide on the anode. Once the deposit has built up to a certain extent, it is peeled off and collected as product manganese dioxide. During the process, hydrogen evolves from the cathode.
Titanium has recently come into use as the anode material for the manufacture of electrolytic manganese dioxide. The reason is that the titanium electrode has outstanding corrosion resistance, specific strength, and workability and also precludes anode-induced contamination of electrolytic manganese dioxide and yields a high quality product.
One problem associated with the use of titanium as the anode for the above process has been the growth of the passive state film on the surface with the increase in current density; it raises the bath voltage accordingly, until the flow of current becomes no longer possible. To avoid this problem, it has been necessary to keep the current density within the range around 0.8 A/dm 2 .
Current density, thus, has a direct bearing upon productivity in the electrolysis industry. The electrolytic cell employed being the same, the higher the current density the larger would be the scale of production that is made feasible. Also, the output being the same, the electrolytic cell could be made smaller in size as the current density increases, reducing the investment in the electrolytic cell to an economical advantage.
Titanium is used as anodes not merely for the production of electrolytic manganese dioxide but also for other applications. With the latter, too, the difficulty is that increased current density induces the growth of a passive state film on the surface with eventual interruption of current flow. To avoid this, modern practice favors plating of the anodes with a noble metal such as platinum.
However, the plating treatment using an expensive noble metal casts a heavy financial burden on the manufacturer. It, thus, presents a major obstacle in the way of the extensive commercial acceptance of the plated anodes.
With these in view, this invention is aimed at providing at low cost a titanium alloy anode which can replace existing titanium anodes and is characterized by the capability of carrying a greater current density.
SUMMARY OF THE INVENTION
The present invention is based upon our discovery, made after intensive research, that titanium containing nickel, preferably in the form of Ti 2 Ni precipitated and dispersed under specific conditions, gives favorable results.
The invention thus provides:
1. an insoluble anode for producing manganese dioxide by electrolysis characterized in that the surface layer or the entire anode is made of a titanium alloy of from 0.5 to less than 15 percent by weight of nickel, the remainder being titanium and unavoidable impurities; and
2. an insoluble anode for producing manganese dioxide by electrolysis characterized in that the surface layer or the entire anode is made of a titanium alloy of from 0.5 to less than 15 percent by weight of nickel, the remainder being titanium and unavoidable impurities, said titanium alloy having thereon Ti 2 Ni particles 300μm or finer in size dispersed uniformly at the rate of at least 10,000 particles per square millimeter of the surface area, whereby the growth of a passive state film is prevented.
In preferred embodiments of the invention:
(A) the surface roughness, Rmax, is 100 μm or above;
(B) the yield strength is 30 kgf/mm 2 or above, and the Vickers hardness 150 or above; and
(C) the flatness is 6 mm or less per meter.
DETAILED DESCRIPTION OF THE INVENTION
In the manufacture of electrolytic manganese dioxide, the objective manganese dioxide deposits on the anode surface with the progress of electrolysis. As long as a low current density is used, no voltage increase takes place even with an anode of pure titanium, as opposed to the case where nothing deposits on the insoluble anode, such as in electroplating or electrolytic winning. It is for this reason that pure titanium, ordinarily unusable as an insoluble anode, can be employed as such in the manufacture of electrolytic manganese dioxide. Nevertheless, the current density must be kept below 0.8 A/dm 2 , at most 1.0 A/dm 2 , for a higher density would cause a gradual rise of the bath voltage with the progress of electrolysis.
This upper limit of current density can be increased by alloying titanium with nickel.
In accordance with the invention, 0.5 percent by weight or more of nickel is added to titanium.
Generally, there are three intermetallic compounds of titanium and nickel: Ti 2 Ni, TiNi, and TiNi 3 . With these compounds it has been found that no increase in bath voltage is observed when current is flowed through each as an anode. Since an insoluble anode must also not dissolve out component metal into the bath, the compounds were all tested with various solutions for corrosion and positive polarization behavior. The results showed that, out of Ti 2 Ni, TiNi, and TiNi 3 , the first-mentioned Ti 2 Ni performed best. Even in strongly acidic aqueous solutions, Ti 2 Ni alone permitted the flow of high density current without any component metal dissolution, up to the oxygen-generating potential.
Thus, Ti 2 Ni has proved to possess very desirable properties as an insoluble anode. However, it is too brittle an intermetallic compound which renders the manufacture of the anode difficult. Another disadvantage is that in environments where oxygen, chlorine, and other gases are produced by long-period electrolysis, the impact of gas evolution causes the Ti 2 Ni to come off. Our further research has revealed that when Ti and Ti 2 Ni are allowed to coexist, Ti makes up for the brittleness of the compound and keeps the latter from coming off. There is no danger of titanium dissolving out, because a passive state film is formed on its surface, enabling the remaining Ti 2 Ni surface to function well as an insoluble anode. It the Ti 2 Ni proportion is too small, a high current density is not attained; hence the lower limit of 0.5 % by weight is specified for Ni.
In preferred embodiments of the invention, Ti 2 Ni is deposited under specific conditions.
As stated above, Ti 2 Ni is highly corrosion-resistant (superior in this respect to pure titanium,) and unlike pure titanium it causes no bath voltage rise due to the formation of an oxide film with the flow of a large current. Thus, we have found that it permits the flow of more current without the danger of corrosion even in quite adverse, corrosive environments. In spite of this, Ti 2 Ni is so brittle that when used alone it is difficult to work, and is practically impossible to employ as an electrode for industrial application. We have now successfully overcome the brittleness of the compound by adding nickel to titanium and dispersing Ti 2 Ni very finely and homogeneously into titanium. In this way, an anode has now been perfected which permits the flow of far more current than pure titanium does.
The Ti 2 Ni particles on the anode surface are desired to be at most 300 μm in diameter, because larger particles will fall off the anode surface during actual operation. Also, uniform dispersion of the Ti 2 Ni particles is a preferred requirement. If the dispersion is nonuniform, uneven current flow will result from the irregular distribution of the particles on the anode surface, leading to a nonuniform growth rate of manganese dioxide. In order to attain a sufficiently high current density, it is desirable that the Ti 2 Ni particles are present at the rate of 10,000 or more per square millimeter of the surface.
The manufacture of such an anode is, for example, by nickel plating of titanium surface followed by thermal diffusion to produce Ti 2 Ni on the surface. Alternately, it is possible to prepare Ti 2 Ni by melting, grinding it into powder, scattering the powder over a titanium surface, bonding the Ti 2 Ni to the titanium surface by heat treatment, and finishing the anode by the combination of rolling plus heat treatment. A considerable simpler approach involves alloying titanium and nickel followed by proper rolling and heat treatment. Anodes for producing manganese dioxide usually take the form of sheets 3 to 6 mm thick, and therefore, an alloy must be made which is workable enough to be rolled down to the above thickness range with good yield. To this end, the alloy is required to contain no more than 15 percent by weight nickel.
For the manganese dioxide-producing anode, it is essential that electrolytic manganese dioxide deposit on the surface during the course of electrolysis. With ordinarily rolled sheets, it has been found that the electrolytically deposited manganese dioxide tends to come off. To avoid the exfoliation, it is now proposed to use a surface roughness, Rmax, of at least 100 μm. The electrolytic manganese dioxide that has deposited after the electrolysis must be removed, e.g., by hammering of the anode or mechanical stripping. This can cause bending or denting of the anode to insufficient strength or hardness. It is for this reason that under the invention the anode is preferably required to have a yield strength of 30 kgf/mm 2 or more and a Vickers hardness of 150 or more.
The anode for manganese dioxide usually must be spaced a certain distance from the cathode. If it is warped or curled, the growth of electrolytic manganese dioxide varies with the location on the anode surface; in an extreme case, shorting can occur. For this reason, the warping or curling must be restricted. Under the invention, a flatness of 6 mm or less per meter is desired.
For the purposes of the invention, the desired properties of the material as an insoluble anode need only be imparted to the electrode surface. There is no special limitation to the electrode substrate. For example, copper with good electrical conductivity may be chosen as the substrate and coated with the material of the invention. The combination will advantageously prevent the heat generation of the electrode with Joule heat and avoid power loss.
The coating material of the invention should be 0.1 μm or thicker. If it is less than 0.1 μm thick, long-period flow of current will cause Joule heat, anodizing, etc. This will expose some substrate surface, leading to serious melting of the particular region.
The invention will be better understood from the following description of the examples thereof.
EXAMPLES
Pure nickel was added in varying proportions to commercially available sponge titanium, and ingots were made by vacuum arc melting. The number of particles of the Ti 2 Ni that emerged on the surface was varied by many different heat treatment and rolling conditions. The products were used as test specimens.
The evaluation method used was as follows. Galvanostatic electrolysis was carried out in the same solution as used in actual operation, so as to form a manganese dioxide deposit on the surface of each test specimen. The bath voltage rise during the process was observed determine the maximum current density the specimen could withstand. The criterion adopted was: when more than 100 hours were required before the bath voltage exceeded 7 V, it was considered that manganese dioxide could be made without difficulty at that current density.
Table 1 summarizes the results of measurements of the time periods required for bath voltage rise when manganese dioxide electrolysis was performed using anodes with varied numbers of Ti 2 Ni particles on the titanium surface. The number of Ti 2 Ni particles was obtained by counting the particles in ten locations on 50 by 50 μm area portions of the specimen surface under a scanning electron microscope (SEM), and then averaging the counts. As can be seen from Table 1, the presence of more than 10,000 Ti 2 Ni particles permits the flow of more current than permitted by pure titanium. Deposition of an even larger number of the particles makes it possible to pass far more current in a stable way.
Table 2 compares the workability of titanium-base alloys containing varied proportions of nickel. It should be clear that the rolling properties deteriorate sharply as the nickel content increases. Particularly when the nickel content exceeds 15 percent by weight, the alloy becomes practically impossible to roll, hot or cold. Hence, the upper limit of the nickel content is 15 percent by weight.
Table 3 compares the degree of adhesion of electrolytic manganese dioxide deposited on the surface of test specimens of anodes with varied surface roughnesses. It will be appreciated that manganese dioxide will not adhere soundly to the surface unless the roughness is more than 100 μm.
It has been confirmed that the manganese dioxide produced using an electrode made by the process of the invention is superior in quality.
An additional advantage is that a high current density may be employed when the electrolysis of manganese dioxide is performed with the electrode of the present invention. If, however, the current density is not increased but kept the same, the bath voltage may be lowered with respect to the bath voltage which would be utilized for a conventional electrode comprising titanium alone.
TABLE 1______________________________________Results of measured time periods required for bathvoltage rise with varied numbers of Ti.sub.2 Ni particleson titanium surfaceNumber ofTi.sub.2 Ni Current Density (A/cm.sup.2)particles/mm.sup.2 1.0 1.2 1.4 1.6 1.8______________________________________ 0 (pure Ti) ◯ x x x x 1000 ◯ x x x x 8300 ◯ x x x x 10500 ◯ Δ x x x 83000 ◯ ◯ ◯ Δ x169000 ◯ ◯ ◯ ◯ ◯______________________________________ ◯ = The bath voltage did not exceed 7 V for over 100 hours. Δ = The bath voltage exceeded 7 V in 50-100 hours. x = The bath voltage exceeded 7 V within 50 hours.
TABLE 2______________________________________Relationship between the nickel content intitanium and workability(containing 0.04 wt % Fe and 0.08 wt % O.sub.2)Ni content (wt %) Hot workability Cold workability______________________________________ 0 (pure Ti) ◯ ◯ 0.1 ◯ ◯ 1.2 ◯ Δ10 ◯ x15 Δ x18 x x______________________________________ ◯ = Workable without difficulty. Δ = Edge or other cracking occurred, but manufacture possible. x = manufacture impossible in mass production.
TABLE 3______________________________________Conditions of manganese dioxide depositionAnode surfaceroughness (Rmax) Adhesion______________________________________As rolled Exfoliation 22 μm " 83 μm "106 μm Adhesion325 μm Good adhesion981 μm "______________________________________
According to this invention, anodes are formed capable of carrying a far greater current than anodes of titanium alone. They have greater corrosion resistance, too. This invention which produces such anodes with excellent electrode characteristics is of great value in that it provides anodes for the industrial production of electrolytic manganese dioxide.
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There is provided an insoluble anode for producing manganese dioxide by electrolysis characterized in that the surface layer or the entire anode is made of a titanium alloy of from 0.5 to less than 15 percent by weight of nickel, the remainder being titanium and unavoidable impurities. The titanium alloy preferably has thereon Ti 2 Ni particles 300 μm or finer in size dispersed uniformly at the rate of at least 10,000 particles per square millimeter of the anode surface area, whereby the growth of a passive state film is prevented.
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BACKGROUND OF THE INVENTION
Local topical anesthetics for the eye are generally used with caution since the decrease in blinking and subsequent dehydration may cause damage to the corneal epithelium. For non-surgical situations, the eye care professional would want anesthesia in the eye which would last only as long as the desired procedure. Such a procedure may be quite short, and there is thus a need for a fast acting and yet transient topical anesthetic for the eye. Such an anesthetic would minimize the keratitis caused by the lack of or decreased rate of blinking.
Injectable anesthetics are used in the eye by retro-bulbar injection to prevent the eye muscles of the patient from moving during sugery. For example, during cataract surgery, the lens of the eye is replaced, and the ophthalmologist will normally anesthetize the retro-bulbar muscles and nerves to keep the eye still during the delicate procedure. Many such surgeons use a combination of drugs to achieve the proper anesthetic profile. For example, lidocaine may have a quick inset while bupivacaine provides a longer action. However, such mixing is an obvious disadvantage.
SUMMARY OF THE INVENTION
An ophthalmic anesthetic, particularly for topical use, has been found in rodocaine. Also part of the invention are ophthalmic pharmaceuticals which contain rodocaine.
DETAILED DESCRIPTION OF THE INVENTION
Rodocaine is the generic name for N-(2-chloro-6-methylphenyl)octahydro-trans-1H-pyrindine-1-propanamide. Another, chemical name for this compound is trans-6'-chloro-2,3,4,4a,5,6,7,7a-octahydro-1H-1-pyrindine-1-propiono-o-toluidide. This compound has the following formula (I): ##STR1##
The synthesis of rodocaine is described in U.S. Pat. No. 3,679,686 to Hermans et al. in Example V.
The pharmaceutically-acceptable, acid-addition salts of rodocaine may be prepared by reaction of the rodocaine free base with the desired acid in the general manner known in the art. Representative salts of the compounds of formula (I) which may be used include those made with acids such as hydrochloric, hydrobromic, hydroiodic, perchloric, sulfuric, nitric, a phosphoric, acetic, propionic, glycolic, lactic, pyruvic, malonic, succinic, maleic, fumaric, malic, tartaric, citric, benzoic, cinnamic, mandelic, methane-sulfonic, ethanesulfonic, hydroxyethanesulfonic, benzene-sulfonic, p-toluene sulfonic, cyclohexanesulfamic, salicylic, p-aminosalicylic, 2-phenoxybenzoic, 2-acetoxybenzoic or a salt made with saccharin.
The use of rodocaine or its salt according to the present invention may be topically or by injection. A typical injection embodiment of the invention would be by retro-bulbar injection to anesthetize the muscles of the patients eye so that the eye will stay still and be free of pain during surgery, e.g. during cataract surgery. The injection vehicles may be any of the typical injection vehicles used in the ophthalmic art, e.g. saline with preservative. The formulation of such an injection may be carried out in a manner similar to Xylocaine®, Lidocaine which is a 4% sterile solution containing hydrochloric acid or sodium hydroxide to adjust the pH to 5.0 to 7.0. The concentration of rodocaine or its salt in such a sterile solution would be about 2% or less, e.g. 0.25% w/v. As used herein, "w/v" indicates weight in grams per milliliter of volume. Thus, 2.5 mg per milliliter would be about 0.25% w/v.
In the injectable embodiment of the invention, the rodocaine or its salt may be combined with a vasoconstrictor such as epinephrine to prevent transport of the anesthetic away from the site of injection. Thus, the anesthetic would stay longer in the site of injection and achieve its desired effect. The amount of epinephrine which could be used in such a combination would be on the order of about 0.001% to 0.002% w/v.
For topical applications, the vehicle used to transport the rodocaine or its salt can be an aqueous saline solution with or without a significant amount of polymer to aid retention in the eye. Polymers which can be used include ethyl cellulose, hydroxypropylmethyl cellulose, carboxymethyl cellulose or polyvinylalcohol in an amount of about 0.5 to 1% w/v. One may formulate the rodocaine or its salt in a manner similar to various commercial artificial tear preparations or may even add the rodocaine or its salt to such preparations to provide an effective topical anesthetic. Commercial artificial tear preparations which can be used include Tearisol from Iolab Pharmaceuticals of Claremont, California, Liquifilm Tears from Allergan Pharmaceuticals, Inc. of Irvine, California and similar preparations. Preservatives may be used, particularly if a multi-use container is contemplated. The preservative of the commercial formulation may be required to be changed in view of possible interaction, e.g. precipitation, with the rodocaine or its salt. Thus, benzalkonium chloride may be deleted with substitution in its place of thimerosal, e.g. 0.002% w/v, chlorobutanol, e.g. 0.5% w/v or methylparaben and/or propylparaben.
The rodocaine or its salt may be used in the topical formulation in an amount of about 1% or less by weight of the vehicle, e.g. 0.5 to 1% by weight based on the volume of said vehicle. Lower concentrations of 0.5, 0.25 or even 0.1% or less of the rodocaine or its salt may be used.
Compared with proparacaine and benoxinate, where corneal sensitivity is blocked for 15-20 minutes with a baseline recovery in 65-80 minutes, rodocaine produces a maximal block within 5 minutes and by 10 minutes, corneal sensitivity increased until it is back to normal at 35-60 minutes.
The corneal epithelial toxicity of rodocaine in concentration of 0.4%, 0.22% and 0.0875% w/v in both preserved and unpreserved formulations indicates minimal effects on corneal epithelium when compared to untreated and phosphate buffered saline treated controls.
EXAMPLE 1
Rodocaine is formulated into seven concentrations by solubilizing in phosphate buffered saline. After baseline corneal sensitivity is established in New Zealand white rabbits using a Cochet-Bonet anesthesiometer, one 25 μl drop of rodocaine is instilled in four eyes per dose. Corneal sensitivity is then measured every five minutes until the baseline is regained.
REFERENCE EXAMPLE 1
In a manner similar to the above, proparacaine, in a concentration of about 0.5% w/v and benoxinate in a concentration of about 0.4% w/v is formulated in commercially available preparations.
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Rodocaine or a pharmaceutically-acceptable salt thereof has been found to be an effective anesthetic in ophthalmology. Topical and injectable formulations are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to illuminated signs and more particularly to illuminated signs having changeable numbers and letters which are protected from the weather in connection with outdoor use in displaying house address numbers.
2. Description of the Prior Art
There are many types of illuminated signs known in the art. In some illuminated signs such as neon signs, the light source is carried in and made a part of the letters, numbers or other characters forming the message on the sign. The letters, numbers and other characters are generally exposed and are not readily changeable.
A second type of illuminated sign is comprised of a translucent front face having letters, numbers or other characters painted thereon with opaque paint and has a light source behind the face such that the entire face of the sign, with the exception of the opaque portions, is illuminated thus providing a visible message during the day or night. The message on this type of sign is not easily changeable.
A third type of illuminated sign is that which is generally used for movie theater marquees and other similar uses. This type of sign is comprised of a translucent face having a light source therebehind and generally having some type of track means on the exterior of the face such that numbers, letters and other indicia characters can be retained in a desired sequence in front of the translucent face so as to spell out the message and be visible at night. The letters, numbers and other indicia are changeable with this type of sign, however, they are generally exposed to the weather which may cause visibility problems such as with snow obscuring some of the characters. Also, gusts of wind may blow some characters from their desired locations thereby reducing the usefulness of the signs.
Thus, there exists a need for an illuminated sign fixture which is suitable for outdoor use, having means allowing for a changeable display message and which is protected from the weather.
SUMMARY OF THE INVENTION
The present invention provides for an illuminated sign comprised of a frame with tracks for receiving indicia plates. The indicia plates are flat card-like members with light transmitting portions therein in the shape of letters, numbers or other characters.
A light source is supplied interior of the tracks such that the light will shine out through the plates thereby displaying the character on the plate. A translucent material is provided between the light and the plate to diffuse the light.
A series of plates are positioned in the tracks to spell out a message such as a name or street address number. The message may be displayed on a single row, or on a plurality of rows.
A transparent cover is frictionally held on the frame to seal the interior of the frame from the weather. The plates are generally of a contrasting color from the translucent material making the light transmitting portions of the plates visible during the day while the light source is turned off.
The plates are easily interchangeable on the tracks such that individualized messages may be economically formed and allowing for the message to be easily and readily changed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an illuminated sign mounted on the exterior wall of a building.
FIG. 2. is a sectional view of the interior of the sign taken generally along the lines II--II of FIG. 1.
FIG. 3 is a partial view of an alternative embodiment for mounting the tracks from FIG. 2.
FIG. 4 is a partial sectional view of the interior of the sign taken generally along the lines IV--IV of FIG. 2.
FIG. 5 is a perspective view of an alternative embodiment of the illuminated sign which can hang from a post and which has a display area on both sides of the sign.
FIG. 6 is a sectional view of the interior of the sign taken generally along the lines VI--VI of FIG. 5.
FIG. 7 is a perspective view of an alternative embodiment of the sign shown in FIG. 5 which can be mounted on the top of a post and which has a display in two rows.
FIG. 8 is a sectional view of the interior of the sign taken generally along the lines VIII--VIII of FIG. 7.
FIG. 9 is a partial view of the means for attaching the middle track shown in FIG. 8.
FIG. 10 is a partial sectional view of the middle track shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, there is generally shown an illuminated sign 10 mounted on the exterior wall 12 of a building 13. The sign 10 is generally rectangular in shape having elongated top and bottom walls 14, 16, short upright side walls 18, 20, a front face 22 having a large surface area, and a rear face 24 mounted against the wall 12 of the building 13.
On the front face 22 there is displayed a message 26 in the form of letters 28, 30, 32 and numerals 34, 36, 38.
The building 13 shown in FIG. 1 has clapboard siding and the sign 10 is sized to have a height approximately the height of one board and is positioned, as is best seen in FIG. 2, up against a protruding portion 40 of an overlapping board 42. This sizing and positioning allows the sign 10 to blend in with the exterior wall 12 of the building 13 and also provides some protection against rain.
The interior construction of the sign 10 is best seen in FIG. 2. A box-like rectangular frame member 44 is comprised of an elongated top wall 46, an elongated bottom wall 48, vertical end walls (not shown) and rear wall 50. The frame member 44 has an open front at 51. The rear wall 50 has at least one hole 52 therein to accommodate an appropriate fastening means 54 such as a screw. The rear wall 50 is to be mounted flush against the exterior wall 12 of the building 13.
A transparent cover member 56 having an open rear at 57, an elongated top wall 58, an elongated bottom wall 60, vertical end walls 62 (second end wall not shown) and a front wall 64 is sized so that the open rear 57 slips over the frame member 44 and is retained frictionally in assembly therewith. There is a sealing rib 66 around the entire circumference of the frame member side walls near the rear wall 50 which engages with a sealing channel 68 formed in the interior of the side walls of the cover member near the open rear 57 such that a water-tight seal is provided between the cover member 56 and the frame member 44.
A slot 70 is formed on the interior of the front wall 64 of the cover member 56 around its perimeter and is defined on one side by the side walls of the cover member 56 and on the other side by a lip portion 72 perpendicular to the front face 64 of the cover 56. A front end 74 of the frame member 44 defining the open front 51 is received in the slot 70.
A short wall 76, integral with the first lip portion 72, is spaced apart from, but parallel to the interior of the front face 64 of the cover 56. The wall 76 and lip 72 form a track defining a groove 78 which extends around the perimeter of the front face 64 of the cover 56. Within this groove 78 is positioned a plurality of plate members 80 as best seen in FIG. 4. The plate members 80 are sized to extend from the grooves 78 near the top of the front face 64 to the grooves 78 near the bottom of the front face 64 so as to be held in a semipermanent position. The plate members 80 are made of a slightly flexible but resilient material such as plastic or thin metal which permits the plate members 80 to be slightly deformed to fit into the grooves 78 and then permits the plate members 80 to resume their normal configuration to be held in the grooves 78.
Referring back to FIG. 2, it is seen that there is a light source 82 which is positioned centrally within the sign 10 and which is supplied with power through lines 84 and 86 by means of a transformer 88. The light source 82 is centrally located such that light falls on the entire interior of the front face 64 of the cover 56. An especially advantageous form of light source is an elongated neon bulb approximately the length of the sign
Additionally, there is provided a translucent sheet 90 between the light source 82 and the plate members 80 which defuses the light striking the plate members 80. The plate members 80, as best seen in FIG. 4, may have light transmitting portions or openings 92 formed therein which permit light from the light source 82 to pass through the plate members 80 and through the transparent cover member 56. The light transmitting openings 92 are shaped to represent various letters, numbers, or other characters so that when a series of plates are aligned in the groove 78, a message is displayed on the front 22 of the sign 10. The translucent sheet 90 provides a uniform brightness along the height of the light transmitting portions 92. Some plate members 80 may be without light transmitting portions and thus would represent spaces or blank areas in the message.
As seen in FIG. 2, the translucent sheet 90 may also be carried in the grooves 78 along with the plate members 80 and would lie against the plate members 80. Also, the translucent sheet 90 may be formed in the same dimensions as the plate members 80 and could be permanently fixed to the back side of the plate members 80. Opaque portions 94 of the plate members 80 which surround the light transmitting portions 92 may be of a color which contrasts with the translucent sheet 90 such that the display message would be readily visible through the transparent cover member 56 during daylight hours when the light source 82 is turned off.
Since the cover member 56 is made of a transparent material, light is easily transmitted through the lip portions 76 and 72 and therefore visible from the exterior of the sign 10. This results in a lighted border around the perimeter of the front face 22 of the sign 10 which may be desirable. If the lighted border is not desired, a masking means 96 such as paint or tape may be applied to the rear wall of the second lip portion 76 to prevent the transmission of light through the cover 56 at that point.
An alternative embodiment of the track and groove means is shown in FIG. 3, where it is seen that the top wall 46a of the frame member 44a has at a front end 74a thereof a pair of spaced apart perpendicular wall members 98, 100 forming a track member and which define a groove 78a therebetween. Thus, the groove 78a is formed as an integral part of the frame member 44a rather than as a part of the front cover 56 as shown in FIG. 2. Therefore, the cover 56a shown in FIG. 3 does not have any interior lips.
In all other respects, the attachment means between the cover 56a and the frame member 44a is the same and the placement of the plate members 80a and the translucent sheet 90a in the groove 78a is also the same. As in the embodiment shown in FIG. 2, the groove 78a in FIG. 3 is to extend at least along the entire length of the top 46a and bottom walls (not shown) of the frame member 44a and can extend around the entire perimeter thereof. With this alternative embodiment, the perpendicular wall 100 which is made of an opaque material will prevent any light from passing through the cover member 56a around the perimeter of the front face 22 of the sign 10 and thus only the light transmitting portions 92a of the plate members 80a will appear illuminated.
Another alternative embodiment is shown in FIG. 5. In this embodiment, the message 26b may be displayed on both the front face 22b and the rear face 24b of the sign 10b. The sign 10b may be hung from a post 102 by means of an outstretched arm 104 having wires 106, 108 depending downward therefrom which are secured to attachment means 110, 112 such as eyes integral with the top wall 46b of the frame member 44b.
As seen in FIG. 6, the construction is essentially the same as described above except the cover member 56b now has a transparent rear face 114 and the top of the cover member 56b is open at 116 to receive the top wall 46b of the frame member 44b. The sealing channel 68b runs around the perimeter of the cover member 56b just below the top opening 116. The sealing rib 66b now runs around the perimeter of the top wall 46b of the frame member 44b. The light source 82b and transformer 88b are carried on the frame member 44b thus requiring the connection between the rib 66b and the channel 68b to support only the weight of the cover member 56b. Two sets of grooves 78b are provided in the frame 44b as described above to accommodate two sets of plate members 80b and translucent sheets 90b.
FIG. 7 shows another alternative embodiment of the present invention wherein a two sided sign 10c is mounted on top of a post 118 and has two message 26d, 26dd displayed on each side, one being positioned over the other. As seen in FIG. 8, the construction of the sign 10c is similar to that shown in FIG. 6, however the cover member 56c is inverted to accommodate mounting the frame member 44c on its bottom wall 48c by appropriate fastening means 118 such as rivets. The sealing rib 66c and sealing channel 68c are now positioned around the perimeter of the bottom wall 48c of the frame member 44c however, in all other respects the attachment of the cover member 56c to the frame member 44c is identical as described above.
Another set of top and bottom grooves 120, 122 are formed in a track member 124 which has spaced apart walls 125, 127 and which extend across the entire face of the sign 10c and which may be positioned equidistant between the top wall 46c and the bottom wall 48c of the frame member 44c. As seen in FIG. 9, the track member 124 is removably secured to the frame member 44c by means of a tongue 128 captured in a groove 130 in the perpendicular frame wall 100c. Thus, the track member 124 can be easily inserted or removed as required.
The plate members 80c and translucent sheets 90c would be sized to be carried between the appropriate spaced apart grooves. The track member 124 may be inserted adjacent both the front face 64c and the rear face 114c to provide for multilevel displays on both sides of the sign 10c. In this manner, any number of levels of messages may be displayed, and any size of display plates may be used by providing an appropriately sized frame member 44c and cover member 56c and appropriately spaced grooves 130 in the wall 100c.
As seen in FIG. 10, the display plate members 80c and defusing sheet 90c are carried in the grooves 120, 122 in the same manner as described above.
For any of the above embodiments, to display a message by using a sign, a person would first select the appropriate display plates having the characters required for the message. Next the transparent cover would be removed from the frame and the display plates would be positioned in the grooves in the appropriate order to correctly display the message. If the grooves extend around the entire perimeter of the frame or cover, the end plates would have to be inserted first and the middle plates would be inserted last, since the sides of the end plates are also secured in position. If the translucent sheet is not attached to the plates, it would also be inserted in the grooves. With the appropriate plates in place, the cover would be slipped back into a locked and weather tight position on the frame and the sign would then be operable.
During daylight hours the message would be displayed due to the contrasting colors of the plates and translucent material and at night the light source could be energized producing a sign in which the characters are illuminated on a dark background. In using the sign for displaying the street address at a home or business, the light source could be wired into the same circuit used for the exterior lighting of the building such that the sign would be "on" whenever the exterior lighting is on. Alternatively, a separate switch could be utilized for energizing the light source used in the sign.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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An illuminated sign for outdoor use is provided which is a frame enclosed by a transparent cover. Grooved tracks are utilized to receive and retain display plates which have light transmitting portions therein in the shape of letters or numbers. A central light source provides illumination and a translucent sheet diffuses the light so that a uniformly bright message appears when the light source is energized and the selected plates are abutted end to end in the tracks. The sign can have a display on more than one side and the display can be in more than one level.
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[0001] This application claims the priority benefit of Korean Patent Application No. 10-2010-0078308, filed on Aug. 13, 2010, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a roll mold, a method for fabricating the same and a method for fabricating a thin film pattern using the same.
[0004] 2. Discussion of the Related Art
[0005] A variety of flat panel display devices to reduce weight and volume of the problems of cathode ray tubes have been introduced. Examples of flat panel display devices include liquid crystal display devices, field emission display devices, plasma display panel devices and electroluminescent (EL) display devices.
[0006] Such a flat panel display device includes a plurality of thin films formed by a mask process including a series of deposition (coating), exposure to light, developing and etching processes. However, the mask process is complicated, thus disadvantageously increasing fabrication costs. Accordingly, recently, research into formation of thin films by an imprinting process using a roll mold 10 , as illustrated in FIG. 1 , is underway.
[0007] Such a roll mold 10 is formed by patterning the surface of a base roller 14 via an etching process. Specifically, an etch-protecting layer and a mask pattern are formed on the surface of the base roller 14 . Next, the etch-protecting layer is patterned through a primary etching process using the mask pattern as a mask. The surface of the base roller 14 is patterned by a secondary etching process using the patterned etch-protecting layer as a mask to obtain a roll mold 10 provided with a groove 12 .
[0008] The roll mold 10 requires two etching processes, thus complicating the overall manufacturing process. The diameter of the base roller 14 is decreased through two etching processes, thus disadvantageously causing variation in the final size of the roll mold 10 and deformation thereof.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is directed to a roll mold, a method for fabricating the same and a method for fabricating a thin film pattern using the same that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0010] It is one object of the present invention to provide a roll mold, a method for fabricating the same and a method for fabricating a thin film pattern using the same, to prevent dimensional variation of the roll mold and simplify the overall manufacturing process.
[0011] To achieve the object and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, provided is a method for fabricating a roll mold including: providing a substrate provided with a master pattern layer; sequentially forming a mold surface layer and a solid buffer layer on the substrate provided with the master pattern layer to provide a flat panel mold; forming an adhesive resin layer on the base roller aligned on the flat panel mold; and rolling the base roller provided with the adhesive resin layer over the flat panel mold to adhere the flat panel mold to the base roller through the adhesive resin layer.
[0012] The surface of the master pattern layer contacting the mold surface layer may be surface-treated with a hydrophobic material such as flurooctyl-trichloro-silane (FOTS) or (heptadecafluoro-1,1,2,3-tetrahydrodecyl)trichlorosilane (HDFS).
[0013] In one embodiment, the step of providing the flat panel mold may include: forming the mold surface layer on the master pattern layer; forming the buffer layer on the mold surface layer, while one end of the flexible substrate is adhered to an unwinder and the other end of the flexible substrate is adhered to a rewinder and keeping the buffer layer level; rolling the base roller over the buffer layer and curing the mold surface layer using a light source arranged in the base roller; and cutting the buffer layer to a size of the mold surface layer, wherein the adhesion of the flat panel mold to the base roller through the adhesive resin layer further includes: curing the adhesive resin layer using the light source in the base roller.
[0014] In another embodiment, the step of providing the flat panel mold may include: forming the mold surface layer on the master pattern layer; forming the buffer layer on the mold surface layer, while one end of the flexible substrate is adhered to an unwinder and the other end of the flexible substrate is adhered to a rewinder and keeping the buffer layer level; and cutting the buffer layer to a size of the mold surface layer, and wherein the adhesion of the flat panel mold to the base roller through the adhesive resin layer further includes: curing the mold surface layer and the adhesive resin layer using the light source arranged in the base roller.
[0015] In accordance with another aspect of the present invention, provided is a roll mold including: a base roller provided with a light source; an adhesive resin layer formed on the base roller; a buffer layer formed on the adhesive resin layer; and a mold surface layer having a groove-protrusion shape formed on the buffer layer, wherein the mold surface layer and the adhesive resin layer are cured through light emitted from the light source arranged in the base roller.
[0016] The mold surface layer may be made of a photocurable mold resin such as urethane-acrylate or polydimethylsiloxane, the buffer layer may be formed of a flexible substrate, and the adhesive resin layer may be made of a photocurable adhesive.
[0017] In accordance with another aspect of the present invention, provided is an apparatus for fabricating a roll mold, including: a stage, on which a substrate provided with a master pattern layer is mounted; a first supply nozzle to apply a liquid mold surface layer onto the master pattern layer; an unwinder and a rewinder to fix both ends of the liquid buffer layer, such that the solid buffer layer is formed on the liquid mold surface layer, while maintaining the solid buffer layer level; a dicing unit to cut the buffer layer to the same size as the mold surface layer; and a second supply nozzle to apply a liquid mold surface layer onto the base roller rolling over the buffer layer.
[0018] The apparatus may further include: a light source arranged in the base roller, the light source curing the liquid mold surface layer and the liquid adhesive resin layer; and a camera removably adhered to the base roller, to align the base roller on the buffer layer.
[0019] In accordance with another aspect of the present invention, provided is a method for fabricating a thin film pattern, including: providing a roll mold comprising a base roller provided with a light source, an adhesive resin layer formed on the base roller, a buffer layer formed on the adhesive resin layer, and a mold surface layer having a groove-protrusion shape formed on the buffer layer; forming a printing liquid on the roll mold or the substrate; and rolling the roll mold over the substrate to form a thin film pattern on the substrate, wherein the mold surface layer and the adhesive resin layer are cured through light emitted from the light source arranged in the base roller.
[0020] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and along with the description serve to explain the principle of the invention. In the drawings:
[0022] FIG. 1 is a sectional view illustrating a conventional roll mold;
[0023] FIG. 2 is a perspective view illustrating a printing or imprinting device for forming a thin film pattern according to the present invention;
[0024] FIGS. 3A to 3E are sectional views illustrating a method for fabricating the roll mold illustrated in FIG. 2 according to a first embodiment;
[0025] FIGS. 4A to 4D are sectional views illustrating a method for fabricating the roll mold shown in FIG. 2 according to a second embodiment;
[0026] FIGS. 5A to 5C are views illustrating a method for patterning a thin film via an imprinting method employing the roll mold of the present invention according to a first embodiment;
[0027] FIGS. 6A to 6C are views illustrating a method for patterning a thin film via a printing method employing the roll mold of the present invention according to a second embodiment;
[0028] FIGS. 7A to 7D are views illustrating a method for patterning a thin film via a printing method employing the roll mold of the present invention according to a third embodiment; and
[0029] FIG. 8 is a perspective view illustrating a liquid crystal display panel formed via the method of fabricating a thin film pattern according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Hereinafter, the present invention will be described with reference to the annexed drawings.
[0031] FIG. 2 is a perspective view illustrating a printing or imprinting device for forming a thin film pattern according to the present invention.
[0032] The printing or imprinting device in FIG. 2 includes a printing liquid supplier 120 and a roll mold 140 .
[0033] The printing liquid supplier 120 stores a printing liquid. The stored printing liquid is supplied to a roll mold 140 using a printing method, or supplied to a substrate 101 using an imprinting method in the process of patterning the thin film.
[0034] The roll mold 140 rotates over a substrate 101 such that it contacts the substrate 101 conveyed by a conveyor 118 . Alternatively, the roll mold 140 may move so as to roll over the substrate 101 while the substrate 101 is fixed.
[0035] A printing liquid from the printing liquid supplier 120 fills a groove 148 of the roll mold 140 by a printing method during the thin-film patterning process. The printing liquid in the groove 148 of the roll mold 140 is transcribed onto the substrate 101 , while the roll mold 140 is rolled over the substrate 101 .
[0036] In addition, the roll mold 140 is rolled over the substrate 101 , to which the printing liquid is applied, using an imprinting method during the thin-film patterning, such that it comes into contact therewith.
[0037] Such a roll mold 140 includes a base roller 144 , an adhesive resin layer 142 , a buffer layer 148 and a mold surface layer 146 .
[0038] The mold surface layer 146 is made of a photocurable material such as urethane-acrylate or polydimethylsiloxane. The mold surface layer 146 is formed so as to have a groove and a protrusion having the same shape as the pattern to be formed on the substrate 101 , or the reverse shape thereof.
[0039] The buffer layer 148 offsets stress applied from the roll mold to the substrate 101 when the roll mold 140 is rolled over the substrate 101 and comes into planar contact with the base roller 144 in the process of fabricating the roll mold 140 .
[0040] The adhesive resin layer 142 adheres the base roller 144 to the buffer layer 148 . In addition, the adhesive resin layer 142 is formed of a photocurable adhesive such as a sealant between the base roller 144 and the buffer layer 148 .
[0041] A light source 122 , as a curing apparatus to cure the mold surface layer 148 and the adhesive resin layer 142 is arranged in the base roller 144 . The light source 122 produces ultraviolet light and is surrounded by a light source housing (represented by reference numeral “ 124 ” in FIG. 3C ). That is, the light source housing 124 surrounds the surface of the light source 122 , except for the surface of the light source 122 facing the stage. At this time, the light source 122 and the light source housing 124 do not rotate together the rotating base roller 144 , instead remaining stationary.
[0042] In addition, a camera (represented by reference numeral “ 126 ” in FIG. 3C ) to assist in aligning the base roller 144 is arranged in the base roller 144 . Specifically, the camera 126 aligns the base roller 144 when the base roller 144 is arranged on the buffer layer 148 and when the base roller 144 , to which the adhesive resin layer 142 has been applied, is arranged on the buffer layer 148 . The camera 126 is removably mounted in the base roller 144 , which is adhered in the process of alignment, and is detached after completion of alignment.
[0043] FIGS. 3A to 3E are sectional views illustrating a method for fabricating the roll mold illustrated in FIG. 2 according to a first embodiment.
[0044] As shown in FIG. 3A , a master pattern layer 112 having a groove pattern 112 a and a protrusion pattern 112 b is formed on a master substrate 110 having a flat surface. The master pattern layer 112 is formed by applying an organic material, which can be stripped, such as photoresist, and patterning the material through photolithography, holographic lithography, laser processing, electron beam processing, focused ion beam processing or the like. Meanwhile, the master pattern layer 112 and the master substrate 110 are separately formed, or a master pattern whose surface has a groove pattern and a protrusion pattern may be formed by patterning the master substrate 110 .
[0045] The master pattern layer 112 may be surface-treated with a self-assembled monolayer (SAM) to facilitate release (detachment) of the master pattern layer 112 from the mold surface layer 146 . Accordingly, adhesion of the masker pattern layer 112 to the roll mold 140 along the mold surface layer 146 can be prevented, when the master pattern layer 112 is released from the mold surface layer 146 . The self-assembled monolayer (SAM) is made of a hydrophobic material such as flurooctyl-trichloro-silane (FOTS) or (heptadecafluoro-1,1,2,3-tetrahydrodecyl)trichlorosilane (HDFS).
[0046] Then, as shown in FIG. 3B , a mold resin liquid is applied through a first supply nozzle 132 onto the master pattern layer 112 to form a mold surface layer 146 . A lower surface of the mold surface layer 146 which contacts the master pattern layer 112 is formed into a protrusion-groove shape along a protrusion 112 b and a groove 112 a of the mask pattern layer 112 . The mold surface layer 146 has a flat upper surface and is formed into a protrusion-groove shape along a protrusion 112 b and a groove 112 a of the mask pattern layer 112 . The mold surface layer 146 is made of a photocurable mold resin liquid such as urethane-acrylate or polydimethylsiloxane.
[0047] Then, as shown in FIG. 3C , the buffer layer 148 , which is rolled on a rewinder 118 and an unwinder 116 and thus maintains a parallel state, is aligned with the mold surface layer 146 . Then, both sides of the base roller 114 are aligned on the buffer layer 148 through an alignment key (not shown) and the camera 126 formed in at least one of a stage 130 , a master substrate 110 , a master pattern layer 112 and a mold pattern layer 146 . The camera 126 performs imaging to confirm whether an alignment key arranged at both sides of the base roller 144 corresponds to both sides of the base roller 144 , thus improving alignment accuracy.
[0048] The base roller 144 aligned on the buffer layer 148 is rolled over the buffer layer 148 . Accordingly, printing pressure generated by the rotation of the base roller 144 is applied to the buffer layer 148 and tension is applied to the buffer layer 148 through the rewinder 118 and the unwinder 116 . In addition, the mold surface layer 146 is cured through the light source 122 arranged in the base roller 144 rotating on the buffer layer 148 .
[0049] Meanwhile, the base roller 144 of the present invention is rolled over the buffer layer 148 , while the base roller 144 comes into planar contact with the solid buffer layer 148 . In this case, the base roller 144 does not slide on the cured solid buffer layer 148 and alignment accuracy between the buffer layer 148 and the base roller 144 is improved, thus improving pattern accuracy. In addition, the solid buffer layer 148 comes into planar contact with the base roller 144 , thus relatively increasing the contact area between the buffer layer 148 and the base roller 144 , and curing the mold surface layer 146 even with a low amount of light and in a relatively short period of time.
[0050] On the other hand, a conventional base roller rotates while directly contacting a liquid mold surface layer without any buffer layer and coming into linear contact with the liquid mold surface layer. In this case, the base roller may slide on the uncured liquid mold surface layer, thus reducing alignment accuracy between the buffer layer and the base roller and reducing pattern accuracy. In addition, the liquid mold surface layer comes into linear contact with the base roller, thus relatively reducing the contact area between the buffer layer and the base roller and necessitating curing of the mold surface layer with a high amount of light for a relatively long time.
[0051] Next, as shown in FIG. 3D , the buffer layer 148 is cut to the same size as the mold surface layer 146 through a dicing process using a dicing unit (not shown) to obtain a flat panel mold including the mold surface layer 146 and buffer layer 148 . At the same time or after a while, the adhesive resin layer 142 is applied onto the base roller 144 through a second supply nozzle 134 . The adhesive resin layer 142 may be applied to the base roller 144 through the first supply nozzle 132 shown in FIG. 3B , instead of through the second supply nozzle 134 .
[0052] Next, as shown in FIG. 3E , the base roller 144 , to which the adhesive resin layer 142 is applied, is rolled over the buffer layer 148 . At the same time, a light source 122 arranged in the base roller 144 is turned on and the adhesive resin layer 142 is cured through light emitted from the light source 122 . Accordingly, the flat panel mold including the mold surface layer 146 and the buffer layer 148 is adsorbed and fixed on the base roller 144 through the adhesive resin layer 142 to obtain a roll mold 140 having a groove and protrusion.
[0053] FIGS. 4A to 4D are sectional views illustrating a method for fabricating the roll mold shown in FIG. 2 according to a second embodiment. This second embodiment is different from the first embodiment in that the mold surface layer 146 and the adhesive resin layer 142 are simultaneously cured.
[0054] Specifically, as shown in FIG. 4A , a master pattern layer 112 having a groove pattern 112 a and a protrusion pattern 112 b is formed on a master substrate 110 having a flat surface. The master pattern layer 112 having a groove pattern 112 a and a protrusion pattern 112 b is formed on a master substrate 110 having a flat surface. Next, as shown in FIG. 4B , a mold resin liquid is applied onto the master pattern layer 112 through the first supply nozzle 132 to form a mold surface layer 146 . Next, as shown in FIG. 4C , the buffer layer 148 which is rolled on a rewinder 118 and an unwinder 116 , and thus maintains a parallel state, is formed on the mold surface layer 146 . Next, the buffer layer 148 is cut to the same size as the mold surface layer 146 through a dicing process using a dicing unit (not shown) to obtain a flat panel mold including the mold surface layer 146 and buffer layer 148 . At the same time or after a while, the adhesive resin layer 142 is applied through the second supply nozzle 134 onto the base roller 144 .
[0055] Next, as shown in FIG. 4D , both sides of the base roller 114 , to which the adhesive resin layer 142 is applied, are aligned on the buffer layer 148 using an alignment key (not shown) and the camera 126 formed on at least one of a stage 130 , a master substrate 110 , a master pattern layer 112 and a mold pattern layer 146 . Next, a light source 122 arranged in the base roller 144 is turned on and the adhesive resin layer 142 is cured through light emitted from the light source 122 . Accordingly, the flat panel mold including the mold surface layer 146 and buffer layer 148 is adsorbed and fixed on the base roller 144 through the adhesive resin layer 142 to obtain a roll mold 140 having a groove and protrusion.
[0056] FIGS. 5A to 5C are views illustrating a method for patterning a thin film via an imprinting method employing the roll mold of the present invention according to a first embodiment.
[0057] As shown in FIG. 5A , a printing liquid 102 is applied to a substrate 101 through a printing liquid supplier 120 . Then, as shown in FIG. 5B , a roll mold 140 including a base roller 144 , an adhesive resin layer 142 , a buffer layer 148 and a master pattern layer 146 is aligned on the substrate 101 . Next, the roll mold 140 is rolled over the substrate 101 . At this time, the printing liquid 102 is cured through a curing apparatus, such as a UV lamp, provided in the base roller 144 of the roll mold 140 , or a curing apparatus provided on the rear surface of the substrate 101 . As a result, as shown in FIG. 5C , the printing liquid 130 is formed in the form of a thin film pattern 104 on the substrate 101 .
[0058] FIGS. 6A to 6C are views illustrating a method for patterning a thin film via a printing method employing the roll mold of the present invention according to a second embodiment.
[0059] As shown in FIG. 6A , a roll mold 140 including a base roller 144 , an adhesive resin layer 142 , a buffer layer 148 and a master pattern layer 146 is provided. The printing liquid 102 supplied from the printing liquid supplier 120 fills the groove of the roll mold 140 .
[0060] Next, as shown in FIG. 6B , the roll mold 140 filled with the printing liquid 102 is rolled over the substrate 101 . Accordingly, the printing liquid 102 is cured through a curing apparatus, such as a UV lamp, provided in the base roller 144 of the roll mold 140 , or a curing apparatus provided on the rear surface of the substrate 101 . Accordingly, the printing liquid 102 is transcribed, dried and cured on the substrate 101 and is thus formed into a thin film pattern, as shown in FIG. 6C .
[0061] FIGS. 7A to 7D are views illustrating a method for patterning a thin film via a printing method employing the roll mold of the present invention according to a third embodiment.
[0062] As shown in FIG. 7A , a roll mold 140 including a base roller 144 , an adhesive resin layer 142 , a buffer layer 148 and a master pattern layer 146 is provided. The printing liquid 102 supplied by the printing liquid supplier 120 fills the groove of the roll mold 140 .
[0063] Next, as shown in FIG. 7B , the printing liquid 102 is transcribed to a transcription roller 106 , which rotates, and, at the same time, is engaged in the roll mold 140 . The transcription roller 106 provided with the printing liquid 102 is rolled over the substrate 101 , as shown in FIG. 7C . Accordingly, the printing liquid 102 is transcribed, dried and cured on the substrate 101 and is thus formed into a thin film pattern, as shown in FIG. 7D .
[0064] As such, the thin film pattern 104 shown in FIGS. 5C , 6 C and 7 D may be used to form thin or thick films on flat panel display devices such as plasma display panels, electroluminescent (EL) display panels and field emission display devices as well as liquid crystal display panels.
[0065] Specifically, the liquid crystal display panel according to the present invention shown in FIG. 8 includes a thin film transistor substrate 180 and a color filter substrate 160 such that a liquid crystal layer 171 is interposed between the thin film transistor substrate 180 and the color filter substrate 160 .
[0066] The color filter substrate 160 includes a black matrix 164 , a color filter 166 , a common electrode 168 and a column spacer (not shown) arranged on an upper substrate 162 in this order.
[0067] The thin film transistor substrate 180 includes a plurality of gate lines 156 and a plurality of data lines 184 which cross each other on a lower substrate 182 , a thin film transistor 168 adjacent to each intersection between the gate lines 186 and the data lines 164 , and a pixel electrode 170 formed at a pixel region provided by the intersection.
[0068] An organic pattern used as a mask for patterning a thin film pattern made of an organic material such as the color filter 166 , the black matrix 164 and the column spacer of the liquid crystal display panel and for patterning a thin film pattern made of an inorganic material such as the thin film transistor 188 , gate lines 186 , data lines 184 and pixel electrode 170 of the liquid crystal display panel may be formed by a printing process using the roll mold according to the present invention.
[0069] The present invention forms a roll mold using application and transcription processes without using any conventional etching process, thus reducing fabrication process complexity and costs, and preventing dimensional variation of a roll mold caused by the etching process. In addition, a process for forming a flat panel mold and a process for adhering the flat panel mold to a base roller are performed in one apparatus in an inline manner. In addition, according to the present invention, the adhesive resin layer and the mold surface layer are cured by at least two light-exposure processes using a light source arranged in a base roller, thus reducing fabrication time and cost. In addition, according to the present invention, the base roller rotates and, at the same time, the flat panel mold is adhered to the base roller, thus increasing the thickness of the flat panel mold and pattern uniformity. In addition, according to the present invention, the roll mold is formed under the conditions of the same tension, roll pressure and heat as in a roll-to-roll imprinting process in which the roll mold rotates to form a thin film pattern, thus compensating for substrate deformation due to tension, pressure and heat in the roll-to-roll imprint process.
[0070] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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Discussed are a roll mold, a method for fabricating the same and a method for fabricating a thin film pattern using the same, to prevent dimensional variation of the mold and simplify the overall process. The method for fabricating a roll mold includes providing a substrate provided with a master pattern layer, sequentially forming a mold surface layer and a solid suffer layer on the substrate provided with the master pattern layer to provide a flat panel mold, forming an adhesive resin layer on the base roller aligned on the flat panel mold, and rolling the base roller provided with the adhesive resin layer over the flat panel mold to adhere the flat panel mold to the base roller through the adhesive resin layer.
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FIELD OF THE INVENTION
The invention relates to a belt transmission, and more particularly, to a belt transmission comprising a first tensioner and second tensioner engaged about an intermediate shaft, the first tensioner and second tensioner each comprising a first arm and second arm and a torsion spring engaged therebetween, the first arm and second arm each bearing upon a surface, the first arm and second arm rotatable by operation of the torsion spring to exert a force upon the intermediate shaft whereby a tension is imparted to a first belt and a second belt engaged with the intermediate shaft.
BACKGROUND OF THE INVENTION
Electric power assist steering systems (EPAS) have been around since the 1960's. Hydraulic power assist steering has traditionally dominated the market. Hydraulic systems have high parasitic energy loss when the hydraulic pump is pumping, but power assist is not required. Early attempts to eliminate this parasitic loss involved fitting an electric motor to the pump and only driving the pump when necessary.
Electric hydraulic assisted power steering systems use an electric motor to drive a hydraulic pump to feed a hydraulic power steering system. These systems are an intermediate step by the industry and their use will likely fade with the increased use of EPAS. EPAS systems allow realization of reduced noise, reduced energy use, active safety features, and adjustability to meet driving conditions. However, the use of these systems has remained limited until recent C.A.F.E. requirements became more difficult to meet. This is driving automotive manufactures to turn to EPAS systems more and more in an effort to improve vehicle fuel economy. EPAS systems eliminate the parasitic losses typically found in hydraulic assist power steering systems.
For example, one difficulty that slowed implementation of EPAS systems was meeting the power requirement with a 12 volt electric motor. Recently systems have been developed that successfully solve this problem. Further, all EPAS systems require a control module to sense driver input and control the electric motor to provide the desired assist. The control module measures driver input torque and uses this to determine the amount of assist required. Assist can be tuned to meet the drivers need depending on driving conditions. The system can even have a tunable “feel” available to the driver.
Even though the main driver for automotive EPAS is fuel economy improvement, EPAS has additional benefits. The system can make steering assist available even when the vehicle's engine is not running. It also enables the use of the automatic parallel parking systems available today.
There are two main types of EPAS systems; column assist and rack assist. Rack assist EPAS systems have an electric motor that is connected to the steering rack. The electric motor assists the rack movement usually through driving a lead screw mechanism. Column assist EPAS systems have an electric motor connected to the steering column. The electric motor assists the movement of the column shaft usually through a worm gear type arrangement. One advantage of these types of systems is the electric motor can be placed in the passenger compartment freeing up valuable space under the hood. This also keeps any sensitive electrical components out of the harsh under hood environment.
Worm drive column assist systems are usually used in small cars where the assist power requirements are lower than what would be needed in a large heavy vehicle. These systems are limited by the speed of the steering wheel and the ratio of the worm drive. The steering wheel at its fastest speed rotates relatively slowly at approximately 60 rpm. With a 60 rpm speed of the steering wheel and a worm drive ratio of 15:1, the max speed of the electric motor would only be 900 rpm. Worm drives are limited to ratios under 20:1 because ratios higher than that cannot be back-driven.
The steering system must be able to be operated with no power. This requires the worm drive be able to operate with the gear driving the worm (back-driven). Having a low motor speed and limited ratio worm drive causes the need for high torque motor. Even with a high torque motor, these types of systems have not been made successful on heavy vehicles. Small vehicles are light and require less steering effort thus enabling the use of these systems. Worm drive column assist SPAS systems are the lowest cost systems and thus also lend themselves to smaller less expensive vehicles.
Typical steering systems with worm drive assists are limited in their efficiency. EPAS systems must be designed to operate when there is no power available. Due to the nature of worm drive's tendency to lock up during back driving when ratios exceed approximately 20:1, worm drive EPAS systems efficiency is not greater than approximately 85% and nearer to 65% during back-driving conditions.
Representative of the art is U.S. Pat. No. 8,327,972 which discloses a vehicle steering system transmission comprising a housing, an input shaft journalled to the housing, an electric motor connected to the housing and coupled to the input shaft, an output shaft journalled to the housing, the input shaft and the output shaft coupled by a first pair of sprockets having a first belt trained therebetween and having a first ratio, the first belt and first pair of sprockets comprising a helical tooth configuration, the input shaft and the output shaft coupled by a second pair of sprockets having a second belt trained therebetween and having a second ratio, and the input shaft and the output shaft coupled by a third pair of sprockets having a third belt trained therebetween and having a third ratio.
What is needed is a belt transmission comprising a first tensioner and second tensioner engaged about an intermediate shaft, the first tensioner and second tensioner each comprising a first arm and second arm and a torsion spring engaged therebetween, the first arm and second arm each bearing upon a surface, the first arm and second arm rotatable by operation of the torsion spring to exert a force upon the intermediate shaft whereby a tension is imparted to a first belt and a second belt engaged with the intermediate shaft. The present invention meets this need.
SUMMARY OF THE INVENTION
The primary aspect of the invention is to provide a belt transmission comprising a first tensioner and second tensioner engaged about an intermediate shaft, the first tensioner and second tensioner each comprising a first arm and second arm and a torsion spring engaged therebetween, the first arm and second arm each bearing upon a surface, the first arm and second arm rotatable by operation of the torsion spring to exert a force upon the intermediate shaft whereby a tension is imparted to a first belt and a second belt engaged with the intermediate shaft.
Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings.
The invention comprises a belt transmission comprising a housing, a first belt trained between a first shaft and a first intermediate shaft, a second belt trained between the first intermediate shaft and a second intermediate shaft, a third belt trained between the second intermediate shaft and a second shaft, a first tensioner and second tensioner each engaged with the housing and each engaged about the first intermediate shaft whereby each tensioner exerts a force upon the first intermediate shaft which thereby imparts a tension to the first belt and to the second belt, and a third tensioner and fourth tensioner each engaged with the housing and each engaged about the second intermediate shaft whereby each tensioner exerts a force upon the second intermediate shaft which thereby imparts a tension to the second belt and to the third belt.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the present invention, and together with a description, serve to explain the principles of the invention.
FIG. 1 is an exploded view of the device.
FIG. 2 is a front perspective view of the device.
FIG. 3 is a back perspective view of the device.
FIG. 4 is a view of the tensioner assembly.
FIG. 5 is an exploded view of a tensioner assembly.
FIG. 6 is a detail of the tensioner assembly in the device.
FIG. 7 is a detail of the input pulley and belt.
FIG. 8 is a detail of the compound pulley sprocket.
FIG. 9 is a diagram of the forces on the shaft of the first compound pulley/sprocket.
FIG. 10 is a diagram of the position of the forces along the input shaft.
FIG. 11 is a diagram of the angular positions of the forces on the input shaft.
FIG. 12 is a detail of the tensioner.
FIG. 13 is a detail of the tensioner.
FIG. 14 is a detail of the force components in the tensioner arms.
FIG. 15 is a perspective view of housing 9 .
FIG. 16 is a perspective view of housing 10 .
FIG. 17 is a perspective view of the assembled housing parts.
FIG. 18 is a plan view of the assembled housing parts.
FIG. 19 is a detail of a tensioner arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is an exploded view of the device. The inventive device comprises a three stage belt drive transmission. Drive stage one comprises a multi-ribbed belt 100 with a drive ratio of 2.4:1. Stage two comprises a toothed or synchronous belt 101 with a ratio of 3.8:1. Stage 3 comprises a toothed or synchrounous belt 102 with a ratio of 3.5:1. The overall drive ratio of the transmission is 31.9:1. Of course, a desired drive ratio can be selected by altering the diameter of the pulleys and sprockets as described herein.
The inventive device comprises input shaft 2 , input pulley 1 , multi-ribbed belt 100 , compound pulley/sprocket 3 , a first intermediate shaft 4 , automatic tensioner assemblies 5 , 6 , 7 , and 8 , a compound sprocket 11 , a second intermediate shaft 12 , a 3 mm pitch toothed or synchronous belt 101 , a 5 mm toothed or synchrounous belt 102 , an synchronous sprocket 13 , housing portion 9 , housing portion 10 , a plurality of bearings ( 50 , 51 , 52 , 53 , 54 , 55 , 56 ), a motor mount 14 , and a plurality of fasteners 15 . A synchronous or toothed belt comprises teeth which extend across a width of the belt.
Input shaft 2 is mounted on bearings 50 , 51 . Input pulley 1 is press fit to input shaft 2 . Bearings 51 and 50 are mounted in each housing 9 and housing 10 respectively, thereby supporting input shaft 2 .
Compound pulley/sprocket 3 is mounted on first intermediate shaft 4 . First intermediate shaft 4 is mounted on bearings 52 , 53 . In turn, bearings 53 , 52 are each mounted within an automatic tensioner 5 and automatic tensioner 6 respectively. Automatic tensioner 5 and automatic tensioner 6 along with bearings 53 , 52 are each in contact with housing 9 and housing 10 , respectively. Compound pulley/sprocket 3 comprises pulley 32 for engaging belt 100 and sprocket 31 for engaging belt 101 .
Second intermediate shaft 12 is mounted on a pair of bearings 54 , 55 . Compound sprocket 11 is mounted to intermediate shaft 12 . Bearings 54 , 55 are each mounted in automatic tensioner 7 and automatic tensioner 8 respectively. Automatic tensioner 7 and 8 with bearings 54 , 55 respectively are each in contact with housing 9 and housing 10 . Compound sprocket 11 comprises sprocket 110 for engaging belt 101 and sprocket 111 for engaging belt 102 .
Output sprocket 13 is mounted on a bearing 56 . Bearing 56 is mounted in housing 10 . Housing portion 9 and housing portion 10 are bolted together using fasteners 15 . Motor mount 14 is bolted to housing 10 . A motor or other driver (not shown) can be mounted to motor mount 14 . Sprocket 13 engages belt 102 .
Multi-ribbed belt 100 transmits power from input pulley 1 to pulley 32 . A multi-ribbed belt comprises ribs that extend in the endless of longitudinal direction of the belt. Belt 101 transmits power from sprocket 31 to sprocket 110 . Belt 102 transmits power from sprocket 111 to output sprocket 13 .
Output sprocket hub 130 is configured to enable connection to a vehicle steering shaft (not shown). Input shaft 2 is configured to allow connection to an electric motor or other power source (not shown). Housing 10 further comprises a bracket 82 , see FIG. 18 , for mounting the inventive device to a vehicle (not shown).
Known tensioners typically comprise a rigidly mounted base and a moveable arm assembly with an idler pulley journalled to the moveable arm. The idler pulley is forceably engaged with a belt by a torsion spring which tensions a belt. Each automatic tensioner 5 , 6 , 7 , and 8 differs from the prior art wherein the prior art tensioner base is replaced by an arm which acts as a second tensioner arm in the inventive device, see FIG. 5 .
Automatic tensioner 5 and 6 act cooperatively to position shaft 4 thereby tensioning belt 100 and belt 101 . Automatic tensioner 7 and 8 act cooperatively to position shaft 12 thereby tensioning belt 101 and belt 102 .
Automatic tensioner 5 and 7 act upon housing 9 . Automatic tensioner 6 and 8 act upon housing 10 , which in turn the combination creates a reaction force upon the movable intermediate shaft 4 . The reaction force exterted on the moveable intermediate shaft 4 positions the shaft to a position of equilibrium based upon the tension in belt 100 and belt 101 . Shaft 4 and pulley 3 move into a position where the belt tension is equal to the combined force pf tensioners 5 and 6 . The same operating principle is realized by tensioners 7 and 8 acting on intermediate shaft 12 and thereby pulley 11 . In this Figure tensioner 5 and tensioner 7 are shown in exploded view. Tensioner 6 and tensioner 8 are not shown in exploded view. Tensioners 5 , 6 , 7 , 8 are of the same design and description.
FIG. 2 is a front perspective view of the device. Housing 9 is omitted from this drawing.
FIG. 3 is a back perspective view of the device. Shaft 2 engages an electric motor or other suitable driver (not shown). Member 82 mounts the device to a suitable mounting surface (not shown). Bearing 52 supports tensioner 6 . Bearing 55 supports tensioner 8 .
FIG. 4 is a view of the tensioner assembly. The inventive automatic tensioner comprises an arm 500 , a bushing 502 , a torsion spring 504 , and an arm 501 . Arm 500 is rotatably connected to arm 501 with bushing 502 providing a low friction surface to facilitate movement. One end 509 of the torsion spring 504 rests against a face 510 on arm 500 . The opposite end 507 of the torsion spring 504 rests against a face 508 on arm 501 . Spring 504 is loaded in the unwinding direction. Arm 500 comprises tangs 503 which hold the tensioner assembly together. Arm 501 comprises tangs 511 which hold the tensioner assembly together. Arm 501 comprises arcuate tensioner surface 506 . Surface 506 contacts a bracket surface 92 on housing 9 , see FIG. 15 . Arm 500 comprises arcuate tensioner surface 505 . Surface 505 contacts a bracket surface 91 on housing 9 , see FIG. 15 . This description is also applicable to automatic tensioners 6 , 7 and 8 .
FIG. 5 is an exploded view of a tensioner assembly. Tensioner 5 receives a bearing 52 which in turn engages shaft 4 . Tensioner arms 500 , 501 are cam like in configuration. The cam like arms rotate around the center of the bearing 52 , namely, the rotation center, see FIG. 19 . Arms 500 , 501 are each configured similarly, that is, a circle within a circle having offset centers and different radii, see FIG. 19 .
Arms 500 , 501 comprise surfaces 505 , 506 respectively which rest on bracket surface 91 and bracket surface 92 , see FIG. 15 . Torsion spring 504 provides a moment to each arm in opposing directions. End 507 bears against tab 508 . End 509 bears against tab 510 . A spring force forcibly rotates the arm surfaces 505 , 506 against surfaces 91 , 92 of the housing 91 , 92 . Since the arms are cam like in operation this causes the rotation center of bearing 52 and thus shaft 4 and pulley 3 to move in a direction which properly tensions belts 100 and 101 . The movement stops when the belt tension is equal to the force of tensioners 5 and 6 . This description is also applicable to operation of automatic tensioners 6 , 7 and 8 as well.
FIG. 6 is a detail of the tensioner assembly in the device. The tensioners operate in pairs, namely, tensioners 5 and 6 act cooperatively to support shaft 4 . Tensioners 7 and 8 act cooperatively to support shaft 12 . Each pair of tensioners forcibly position shaft 4 and shaft 12 which provides the force necessary to properly tension the belts.
For the two belts ( 101 , 102 ) engaged with each compound pulley/sprocket ( 3 , 11 ) the tensioning force is preferably oriented such that the proper force in the proper direction is applied to create the desired tension in each belt.
Proper belt tension depends on the diameter of the pulley and the desired torque in the system. For example, a torque input to input pulley 1 is 1.88 Nm and the pulley diameter is 30 mm. This yields a force of 125.3N (or ΔT=125.3N) applied to belt 100 by pulley 1 . This is the difference in tension in belt 100 due to torque regardless of the installed tension in the belt.
Torque=Force×distance
Torque=1.88 Nm
Distance=Diameter/2=0.030 m/2=0.015m
Force=Torque/distance
Force=1.88 Nm/0.015m
Force=125.3N
FIG. 7 is a detail of the input pulley and belt. The difference between the tight side tension and the slack side tension of belt 100 is 125.3N. The slack side tension cannot drop below a certain value without the drive slipping. This value is determined with the calculation of the minimum tension as follows:
T
2
T
1
=
ⅇ
μθ
Where T 2 =tight side tension
T 1 =slack side tension μ=friction=1 Θ=wrap angle on pulley=139.7 degrees
Solving for T 2 :
T 2 =T 1 e μθ
Additionally the torque is equal to the radius of the pulley times the difference between the tight side tension and the slack side tension:
Torque= r*ΔT=r ( T 2 −T 1)
Substituting for T 2 and solving for T 1 :
T
1
=
Torque
R
(
ⅇ
μθ
-
1
)
T
1
=
1.88
0.015
(
ⅇ
1
*
2.72
-
1
)
T
1
=
12.0
N
Since ΔT=125N we get T 2 =137.3N
The value calculated above for T 1 is the minimum value so a factor of safety is added to the system, for example, this value is doubled to 24N which gives a tight side tension of 149.3N for belt 100 . When there is no torque in the drive, the tight side and slack side tensions equalize to become the installed tension. The magnitude of that is one half the total tension:
Installed
tension
=
T
1
=
T
2
=
1
2
total
tension
=
1
2
(
149.3
+
24
)
=
86.6
N
The hubload is then the resultant of the sum of these tension forces applied at the angle of the belt. To determine the angle of the belt we need to know the wrap angle of the belt around the pulley. Simple geometry yields the following formula for wrap angle:
WA=π− 2 sin( R 2 −R 1/center distance)
Where:
R 2 =radius of opposing pulley=36 mm R 1 =radius of subject pulley=15 mm Center distance=the distance between the centers of the pulleys=61 mm
This results in a wrap angle of 139.7 degrees.
The angle of the tension force is:
Tension force angle= TFA =(180− WA )/2
TFA =(180−139.7)/2
The belt tension forces are at angles of +/−20.15 degrees from the line formed between pulley centers.
The hubload (HL) is then:
Hubload=2(installed tension*cos( TFA ))
HL= 2*(86.6*cos(20.15))=162.6N
The hubload is applied along a line formed through the centers of each pulley pair at the mid width of the belt. The force on the output pulley is equal and opposite the force on the input pulley.
When the pulley is a compound pulley or sprocket, see FIG. 8 , the hubload must be determined for both belts and applied in the appropriate direction and location along the shaft. FIG. 8 is a detail of the compound pulley sprocket 3 . Since the forces on each shaft cancel, it is possible to calculate the forces necessary from each tensioner to balance the hubloads on the shaft.
FIG. 9 is a diagram of the forces acting on the shaft 4 of the first compound pulley/sprocket 3 . FIG. 10 is a diagram of the position of the forces along the input shaft 4 . FIG. 11 is a diagram of the angular positions of the forces on the input shaft 4 .
FH 1 is the force of hubload from belt 100 .
FH 2 is the force of hubload from belt 102 .
FT 1 is the force from tensioner 1 .
FT 2 is the force from tensioner 2 .
In order to determine the forces required in each tensioner, the calculation is simplified by separating the calculations into the forces from each belt and then adding them together. The forces are resolved into an x component and a y component. The x axis is normal to a line formed between the centers of the pulleys of the input drive (z-axis). Considering the x direction from FH 1 we get:
Given:
FH 1 =157.2N FH 2 =600N β=85 deg FH 1 is in the positive X direction z 1 =33.5 mm Z 2 =48.0 mm Z 3 =13.5 mm
Summing the forces in the X direction (see FIGS. 7, 8, and 9 ):
0= FH 1− FT 2 x−FT 1 x
Where:
FT 2 x is the force from tensioner 2 in the x direction.
FT 1 x is the force from tensioner 1 in the x direction.
Summing the moments about point A ( FIG. 10 ):
0=− FH 1* z 1+ FT 1 x*z 2
FT 1 x =( z 1/ z 2)* FH 1
Then:
FT 1 x= 109.7N
Substituting:
FT 2 x=FH 1− FH 1 x
FT 2 x= 47.5N
Repeating the calculations for the x direction from FH 2 :
FH 2 cos β= FT 2 x′+FT 1 x′
FT 2 x′=FH 2 cos β− FT 1 x′
Summing moments about A:
0=− FH 2 cos β* z 3+ FT 1 x′*z 2
FT 1 x′=FH 2 cos β*( z 3/ z 2)
FT 1 x′= 14.7N
Substituting:
FT 2 x′=FH 2 cos β− FT 1 x′
FT 2 x′= 37.6N
Adding the respective forces in the x direction for the tensioners gives:
FT 1 x″=FT 1 x+FT 1 x′
FT 1 x″= 109.7N+14.7N=124.4N
And
FT 2 x″=FT 2 x+FT 2 x′
FT 2 x″= 47.5N+37.6N=85.1N
Repeating these calculations for forces in the Y direction yields:
FT 1 y″= 168.1N
FT 2 y″= 583.0N
Geometry informs the magnetude of FT 1 and FT 2 by:
FT 1=√{square root over ( FT 1 x″ 2 +FT 1 y″ 2 )}
FT 2=√{square root over ( FT 2 x″ 2 +FT 2 y″ 2 )}
FT 1=209.1N
FT 2=589.2N
From this, simple geometry gives us the angles of these forces:
Θ= a sin( FT 2 y″/FT 2)=81.7 deg
α= a sin( FT 1 y″/FT 1)=53.5 deg
Similar determinations of tensioner force can be made for each tensioner position and then each tensioner can be configured to create the required force. Table 1 below is a summary of the required tensioner forces. The values in Table 1 are provided only as examples and are not intended to limit the scope of the invention.
TABLE 1
Belt
angle
Tens
Tens.
Input
Output
inst.
Hub
between
Tens.
force 1
Tens.
force 2
Torque
Torque
Tension
load
stages
force 1
angle
force 2
angle
(Nm)
(Nm)
(N)
(N)
(deg)
(N)
(deg)
(N)
(deg)
Interm.
Stage 1
1.88
4.51
86.64
162.68
85.00
137.19
19.40
635.18
81.88
Shaft 4
Stage 2
4.51
17.14
368.59
647.14
Interm.
Stage 2
4.51
17.14
368.59
647.14
88.00
967.18
80.70
1633.23
71.68
Shaft
Stage 3
17.14
62.13
942.03
1669.02
12
FIG. 12 is a detail of the tensioner. Again turning to tensioner 5 , each arm 500 , 510 has a rotation center about the center of shaft 4 , also see FIG. 19 . Torsion spring 504 simultaneously applies a rotational force to each arm 500 , 501 . The arms function as an opposing pair with the same torque being applied to each arm. Each arm surface 505 , 506 rests against a surface of the housing 9 , namely 91 , 92 respectively. The torque applied to the arms by the torsion spring 504 causes them to rotate. The resulting rotation causes the tensioner center of rotation, and thereby the center of shaft 4 , to move. The center of rotation moves until an opposing force prevents it, namely belt tension. The opposing force which equilibrates the system is the desired belt tension force.
Each arm 500 , 501 has a circular profile at the contact surface 505 , 506 respectively. The distance between the tensioner rotation center (shaft 4 center) and a line perpendicular to the bracket surface 91 at the point of contact with the arm surface 505 , see FIG. 12 and FIG. 19 , is the effective tensioner arm length “E”. The effective arm length E changes with the rotation of the tensioner arms.
FIG. 13 is a detail of the tensioner. In FIG. 13 line A is perpendicular to the bracket surface 91 and is perpendicular to line a. Line B is perpendicular to line b. The effective arm length E is the distance from line A to the rotation center along line a.
The center of curvature of the arm surface is offset a fixed distance from its center of rotation. The effective arm length is equal to the offset only when lines A and B are coincident with one another. When lines A and B are not coincident, the effective arm length is less than the center offset (CO) as a function of the angle formed between the lines.
E =Effective arm length= CO *cos(ω)
Given:
CO=6 mm ω=8 deg
Effective arm length=6 cos(8)=5.94 mm
The force from each tensioner arm is equal to the torque on the arm divided by the effective arm length.
Knowing the force required of the tensioner acts against the angular surfaces of the housing, for example, 91 , 92 , at the point of contact of the tensioner arm and the surface, one can determine the force required at these surfaces and from that, the torque required in the tensioner arm.
Given:
SA=Surface 91 angle=30 deg
TF=Tensioner force=635N
Then:
Arm force=( TF/ 2)*cos( SA )
AF =(635/2)*cos(30)
AF= 275N
The torque required in the arm is simply the arm force (AF) times the effective arm length (EAL).
Torque= AF*EAL
T= 275N*0.00594 m=1.63 Nm
Tensioners 5 , 6 , 7 , 8 are designed such that as the arms rotate, the effective arm length is reduced. Each respective torsion spring ( 504 , 604 , 704 , 804 ) also provides less torque as the tensioner arms rotate. If the torsion spring has a spring rate of 0.01 Nm/deg and the arms rotate 20 degrees, then the torque from the spring drops by 0.2 Nm. The effective arm length changes from the above 5.94 mm to 5.30 mm. The resulting tensioner arm force remains nearly constant at 270N.
The included angle of the faces of the housing surfaces 91 , 92 can range between 180 deg to 90 deg giving a surface angle of 0 deg to 45 deg as described above, see FIG. 14 , FIG. 15 and FIG. 19 .
If the angle between surfaces 91 , 92 is 0 degrees, there is no horizontal force component from the tensioner arms. Surface angles greater than zero causes the tensioner to self center due to the horizontal component of the force being equal and opposite from each tensioner arm. If the surface angle exceeds 45 degrees, these horizontal components exceed the tensioning force. This creates a condition of “diminishing returns” on the spring torque. As the spring torque is increased, the horizontal component of tensioner force grows more than the tensioning force.
FIG. 14 is a detail of the force components in the tensioner arms. Vector “A” indicates the force on surface 505 exerted by surface “TS” at the point of contact between 505 and TS. Vector “B” indicates the force on surface 506 exerted by surface “TS” at the point of contact between 506 and TS. Surface TS is analogous to surface 91 and surface 92 . Surface TS depicts the 180 degree condition between surfaces 91 , 92 . Given the offset of each tensioner arm 500 , 501 , see FIG. 5 and FIG. 19 , vectors A and B are not co-axial.
FIG. 15 is a perspective view of housing 9 . Housing 9 comprises bracket surface 91 and bracket surface 92 . Tensioner surface 505 and tensioner surface 506 engage surfaces 91 and 92 respectively.
FIG. 16 is a perspective view of housing 10 . Bearing 50 engages receiving portion 80 . Bearing 56 engages receiving portion 81 . Tensioner surface 805 engages surface 91 c . Tensioner surface 806 engages surface 92 c . Tensioner surface 605 engages surface 91 a . Tensioner surface 606 engages surface 92 a.
FIG. 17 is a perspective view of the assembled housing parts. Bracket 82 on housing 10 provides means to attach the device to a mounting surface (not shown). Tensioner 5 engages surfaces 91 and 92 . For tensioner 6 , arcuate surfaces 605 and 606 engage surfaces 91 a and 92 a respectively. For tensioner 7 , arcuate surfaces 705 and 706 engage surfaces 91 b and 92 b respectively. For tensioner 8 , arcuate surfaces 805 and 806 engage surfaces 91 c and 92 c respectively.
FIG. 18 is a plan view of the assembled housing parts.
FIG. 19 is a detail of a tensioner arm. Rotation center (RC) is the point about which the arm 500 rotates during operation. RC also coincides with the axis of rotation of shaft 4 . The arm profile center (PC) is the center of curvature of surface 505 , see FIG. 13 . The distance between the two points is the offset. The rotation center radius (R 1 ) is less than the radius of curvature (R 2 ) of surface 505 . This description is also applicable to arm 501 . This description for FIG. 19 also applies to each of the arms for tensioners 6 , 7 and 8 .
Although a form of the invention has been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts and method without departing from the spirit and scope of the invention described herein.
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A belt transmission comprising a housing, a first belt trained between a first shaft and a first intermediate shaft, a second belt trained between the first intermediate shaft and a second intermediate shaft, a third belt trained between the second intermediate shaft and a second shaft, a first tensioner and second tensioner each engaged with the housing and each engaged about the first intermediate shaft whereby each tensioner exerts a force upon the first intermediate shaft which thereby imparts a tension to the first belt and to the second belt, and a third tensioner and fourth tensioner each engaged with the housing and each engaged about the second intermediate shaft whereby each tensioner exerts a force upon the second intermediate shaft which thereby imparts a tension to the second belt and to the third belt.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to agricultural irrigation and more particularly to applying water to the land from a pipe which moves, as it waters, laterally of its length.
(2) Description of the Prior Art
In commercial practice today agricultural fields are often watered by sprinkling from a moving pipe. Most of these irrigation systems are center pivot type. The water is sprinkled from the pipes which constantly move as they irrigate.
Certain irrigation devices have discharged water through socks or soakers. For example, SCHEUTMAAT, U.S. Pat. No. 2,174,600.
LANNINGER, German Pat. No. 348102, discloses irrigation system having a discharge close to the ground.
SUMMARY OF THE INVENTION
New and Different Function
I have discovered that water can be applied to land much more efficiently by running the water through a sock or short flexible hose directly into the furrow to be watered. There is less evaporation than if the water is sprinkled on the ground. There is also less power required because the only pressure required on the water is for even distribution from the pipe. The water is evenly distributed especially if the land to be irrigated is furrowed and diked. Therefore I achieve a better distribution of water, less evaporation and at less power than by the previous methods of irrigation.
Thus it may be seen that the total function of my invention far exceeds the sum of the functions of the individual elements such as pipes, hoses, valves, etc.
Objects of this Invention
An object of this invention is to irrigate cultivated agricultural land.
Further objects are to achieve the above with a device that is sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, adjust, operate and maintain.
Other objects are to achieve the above with a method that is versatile, ecologically compatible, energy conserving, rapid, efficient, and inexpensive, and does not require skilled people to install, adjust, operate and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of a center pivot system embodying this invention.
FIG. 2 is a perspective view of a portion of a lateral system embodying this invention.
FIG. 3 is a sectional view taken on line 3--3 of FIG. 1 showing a side sectional view of the equipment with the diked furrows being watered.
FIG. 4 is a top plan view of the system taken on line 4--4 of FIG. 2 showing the system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there may be seen a standard center pivot system such as ZIMMATIC manufactured by Lindsay Manufacturing Company, Lindsay, Nebr., a subsidiary of Dekalb Agresearch, Inc. Such a system includes an elongated pipe 10 carrying water. The pipe is supported above the ground by a plurality of vehicles 2, each vehicle having wheel 14. The vehicles 12 will support the pipe 10 a set distance above the land to be watered. There is a move means such as an electric or water motor 16 attached to the vehicles for moving the pipe with the water therein over the land. Supply means such as the center pivot 18 is attached to the pipe for supplying water to the pipe as it moves.
Those having ordinary skill in the art will recognize that the system as described at this point is well known and commercially available on the market.
The system also has a plurality of outlets 20 for discharging the water from the pipe 10. According to my invention an inverted U pipe 22 is attached to the outlet 20 and a drop pipe 24 is attached to the U pipe. The drop pipe terminates at point 26 above the level of the land 28 to be irrigated. There is connected a drop pipe extension 30 which extends at a angle of 135° to the drop pipe 24 and which extends at a 45° angle to the land 28.
Short flexible drop hose 32 is attached to the drop pipe extension 30. It may be seen that the drop pipe extension 30 terminates at a point 34 also above the level of the land 28 to be irrigated. However the length of the drop hose 32 is such that not only it reaches the land to be irrigated and the bottom 36 of the furrow in the land but also it has a portion 38 which drags along the bottom of the furrow. It may be seen in FIG. 1 for the drop hose 32 to drag along the furrow that it is necessary for the land to be plowed in a circle. That is to say the furrows each have circular configuration having the center pivot 18 as their center. The system is well adapted for irrigating fields having a growing crop 40 growing on top of the beds 42 between the furrows with bottoms 36.
To prevent the water from evaporating or running at a distance from where it is placed, dikes 44 are formed along within the furrows. Equipment for forming the dikes is well known. Normally the dikes will be placed at a spacing of about 2 or 3 times the furrow spacing. That is to say that if the furrows are spaced 40 inches apart that the dikes would be spaced about 80 inches or 120 inches apart. This spacing may vary. However I have found it desirable that the spacing for the dikes be no more than 6 times the furrow spacing. That is to say if the furrows are 40 inches apart, the dikes should be no more than 20 feet apart.
This system is particularly adapted for supplemental irrigation for crops grown in semi-arid land. In areas where there is sufficient rainfall to support a minimum crop, this system is good to provide additional water so that a superior crop may be grown. Normally in such areas the crops are planted in a spaced pattern, Normally there are two rows of planted crop and one or two rows skipped. In such instances the land is watered only in the furrow between the two planted rows. That is to say that the drop pipes 24 would be spaced only in every third furrow if the crop were planted two in and one out (two rows planted, one row skipped) or they would be spaced only in every fourth furrow if it were planted two in, two out.
FIGS. 2 and 4 show a embodiment of this invention attached to a lateral move system with straight rows. That is to say that FIG. 2 shows a system having an elongated pipe 110 supported by a plurality of vehicles 112 each having wheels 114. Only one vehicle has been shown in FIG. 2, but those with skill in the art will understand that there would be a plurality of vehicles. Also the vehicles as shown in FIG. 2 would have a move means 116 attached to the vehicle for moving pipe 110 over the land to be irrigated. Supply means in the form of a supply hose 118 having one end attached to the supply pipe 119 and the other with the elongated elevated pipe 110 supplies water to the elevated elongated pipe 110 as it moves.
Again, those familiar with the system will understand that the embodiment as shown in FIG. 2 as described to this point, is old and commercially available on the market from, for example, Zimmatic by Lindsay Manufacturing Company, supra. To this standard system drop pipes 124 are attached to outlet nipples 120 depending from the elevated elongated pipe 110. On bottom of each of the drop pipes is connected the flexible drop hose 132.
As with the previous embodiment the drop pipe 124 will terminate at a point 134 above the land 28 to be watered and the drop hose will have a portion 138 which drags in the bottom 136 of the furrows between beds 142 having growing plants 140 thereon. As previously indicated there will be additional beds 141 not having a plant growing thereon in a two in, one out planted pattern. There will be drop pipes and drop hoses only between the two rows or beds 142 having plants 140 growing thereon. The furrows of FIG. 4 also show the dikes 144 therein. These dikes will not necessarily be exactly spaced, as are the furrows. However the spacing between the dikes will be less than six times the row spacing and more generally about two or three times the furrow spacing.
As may be seen in both instances the elongated pipe is at right angles to the rows and furrows to be irrigated. Of course in the embodiment shown in FIG. 1, the elongated pipe revolves around the center pivot, but it is also at right angles to the row and it moves laterally or along the row. This is certainly true of the embodiment shown in FIG. 2. That is to say that the elongated elevated pipe is at right angles to the row, that the movement is laterally of the pipe along the row. Water is discharged from the open terminal end of the drag hose 32 and 132.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements is provided:
______________________________________10 110 elongated pipe12 112 vehicles14 114 wheel16 116 move means18 118 supply means-- 119 supply pipe20 120 outlets22 -- u pipe24 124 drop pipe26 -- terminal point28 -- land30 -- external pipe32 132 drop hose34 134 terminal point36 136 b. furrow38 138 drag port40 140 crop-- 141 added bed42 142 bed44 144 dike______________________________________
The embodiments shown and describe above are only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the proportions, material, arrangement, and operation, and still be within the scope of my invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description of the specific examples above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention.
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A furrowed irrigated field is diked and water is applied to the furrows. The water is prevented from running down the furrows by the dikes and therefore stays in the approximate location where applied. The water is applied to the furrows from an elevated pipe at right angles to the furrows. The pipe moves along the furrows. At each furrow to be irrigated, a drop pipe extends downward, terminating a short distance above the ground. A sock or flexible drop hose is attached to the end of the drop pipe. The hose drags along the ground so that there is a minimum of erosion to the soil or evaporation of the applied water.
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BRIEF SUMMARY OF THE INVENTION
1. Technical Field
This invention relates to reactive polymers, e.g., aqueous emulsion polymers, having pendant flexible or dangling side chains prepared from ethylenically unsaturated carbodiimides, e.g., carbodiimide (meth)acrylates. The reactive polymers contain ethylenic unsaturation near the surface or in the surface area of the particles that form the polymers, the ethylenic unsaturation being connected to the polymer through the pendant flexible or dangling side chains. This invention also relates to the process for preparing the reactive polymers, to crosslinkable formulations based on the reactive polymers, and to thermoplastic and crosslinked films prepared from the reactive polymers. The reactive polymers are useful as decorative and functional coatings, inks, adhesives, textile coatings and sealants.
2. Background of the Invention
Aqueous emulsion polymers or latexes in both clear and pigmented form are well-known, widely-used articles of commerce. Examples of these uses include interior and exterior architectural coatings, general metal coatings, adhesives, and the like. The latexes are formed by aqueous emulsion polymerization of monoethylenically unsaturated monomers as styrene, butyl acrylate, methyl methacrylate, vinyl acetate, acrylic acid, glycidyl acrylate, 2-hydroxyethyl acrylate, and similar compounds. When ethylenically unsaturated monomers that contain a functionality other than unsaturation, such as the carboxyl group in acrylic acid, and the hydroxyl group in 2-hydroxyethyl acrylate, are used, there is a propensity for these groups to be found at or near the surface of the emulsion particles because of the affinity of the groups for the aqueous environment. In addition, techniques for increasing the amount of any non-water reactive functional group near the surface of the emulsion particles are known to those skilled in the art of emulsion polymerization. Illustrative of such techniques is the production of a core and shell latex in which a the core of the particles has a given composition that may contain a small amount of the functional groups or be devoid of them and the shell or outer layers of the particle have a different composition which may be rich in the functional groups, and the like.
There is a need for products that have improved, lower initial molecular weight characteristics, improved adhesion, and products that will crosslink under ambient conditions or low to moderate temperatures in the presence of air.
DISCLOSURE OF THE INVENTION
This invention relates in part to a polymer having one or more pendant flexible side chains connected thereto, wherein said pendant flexible side chains contain ethylenic unsaturation and are connected to said polymer by an N-acyl urea linkage, said N-acyl urea linkage formed by the reaction of an ethylenically unsaturated carbodiimide with a carboxylic acid group on said polymer.
This invention also relates in part to a process for preparing a polymer having one or more pendant flexible side chains connected thereto comprising:
(a) preparing a precursor polymer having carboxyl group functionality from one or more ethylenically unsaturated monomers;
(b) post reacting the precursor polymer with one or more ethylenically unsaturated carbodiimides; and
(c) optionally recovering the step (b) polymer and redissolving it in an organic solvent.
It has been found that ethylenic unsaturation of various types can be formed on, in, or near the surface of polymer particles that contain free, reactive carboxylic acid functionality by first preparing a precursor polymer and then post reacting it with one or more ethylenically unsaturated carbodiimides, e.g., carbodiimide (meth)acrylates, containing a functional group that will react with all or a portion of the free, reactive carboxyl functionality on the precursor polymer particle. The post reactant will contain an ethylenic unsaturation group that can air dry or force dry into a crosslinked, solvent resistant coating with broad utility characteristics. Air dry means to cure the liquid coating into a solid film by allowing it to remain under ambient conditions for a period of time sufficient to effect solidification. Force dry means to cure the liquid coating into a solid film by exposing it to a thermal source such as an oven, to an actinic radiation source such as ultraviolet light, as electron beams, as lasers, and the like with or without a predrying step under ambient conditions to remove water, solvent, or other carrier. For purposes of this invention, ethylenic unsaturation shall include all permissible compounds, groups or substituents having at least one carbon-carbon double bond including, for example, (meth)acrylates, vinyls, allyls, alkenes and the like.
In an embodiment of this invention, the post modified polymer containing ethylenic unsaturation is recovered from the aqueous environment, dissolved in an organic solvent, and applied to a substrate to effect air-cure crosslinking. In specific embodiments of this invention, the water-borne polymer particles can be crosslinked with free radicals generated from an actinic energy source such as an electron beam or by formulation with a free radical-generating photoinitiator and, if necessary, a synergist, and exposed to an ultraviolet light source such as sunlight, mercury vapor lamps, xenon lamps, etc.
In another embodiment of the invention, the polymer precursor containing free, reactive carboxyl functionality can be recovered from the aqueous media and dissolved in an organic solvent or can be prepared in an organic solvent. The polymer in organic solvent can be modified by post reaction with one or more of the above described reactants for aqueous systems to form a polymer with pendant flexible chains having ethylenic unsaturation connected thereto that can be crosslinked under ambient, air-cure conditions or radiation-cure conditions.
In a further embodiment of the invention, the post modified polymers containing ethylenic unsaturation neat or formulated with photoinitiator and/or other radiation-reactive chemicals is recovered as a solid, uncrosslinked film by removal of either the aqueous or organic solvent media. The solid film is then used as a photoresist in the manufacture of printed circuit boards or other article by selective exposure to radiation. Selective exposure is provided by a mask through which radiation does not penetrate.
The reactive polymers of the invention can be used in a variety of ways including but not limited to clear, colored, filled, or pigmented crosslinked latexes, water-borne alkyds, solvent-borne alkyds, radiation curable systems, and the like. Illustrative of generalized utility areas are coatings for metal, paper, plastics, wood, and masonry; inks; adhesives; binding agents for concrete; photoresists; and the like. Among the specific coating end uses that can be mentioned are interior and exterior architectural coatings, can coatings, office and home furniture coatings, pipeline coatings, sign coatings, maintenance coatings, business machine coatings, functional and decorative automotive coatings, textile coatings, conformal coatings, electrical and electronic coatings and the like.
DETAILED DESCRIPTION
Carboxyl group functionalized polymer particles can be reacted with one or more ethylenically unsaturated carbodiimides, e.g., carbodiimide (meth)acrylates, in which the reaction takes place with a carboxylic acid group to form a free ethylenically unsaturated terminated, pendant flexible side chain connected to the polymer particle through an N-acyl urea linkage. For purposes of this invention, the term "N-acyl urea linkage" is contemplated to include all permissible linkages resulting from the reaction of an ethylenically unsaturated carbodiimide with a carboxylic acid group on the polymer which links an ethylenically unsaturated terminated. pendant flexible side chain to the polymer.
The polymers having carboxyl group functionality can be prepared from a variety of monoethylenically unsaturated monomers including, for example, acrylates and methacrylates (both referred to herein as (meth)acrylates); vinyl esters; vinyl aromatic, cycloaliphatic, and heterocycles; hydroxyalkyl (meth)acrylates and their derivatives; vinyl halogens and vinylidine halogens; alkenes and substituted alkenes; nitriles; and vinyl ethers. If desired, minor amounts of di- or triethylenically unsaturated monomers can be used if they do not unduly interfere with the polymerization process by causing excessive crosslinking and unusable polymer formation. Various carboxylic acid monomers can be used, such as acrylic acid, methacrylic acid, ethacrylic acid, alpha-chloroacrylic acid, crotonic acid, fumaric acid, citraconic acid, mesaconic acid, itaconic acid, maleic acid and the like including mixtures thereof. Illustrative of the (meth)acrylates are methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylates, butyl (meth)acrylates, pentyl (meth)acrylates, hexyl (meth)acrylates, heptyl (meth)acrylates, octyl (meth)acrylates, nonyl (meth)acrylates, decyl (meth)acrylates, and the like. Illustrative of the vinyl esters are vinyl acetate, vinyl propionates, vinyl butyrates, vinyl pivalates, vinyl hexanoates, vinyl hepanoates, vinyl octanoates, vinyl isovalerate, vinyl 2-ethylhexanoate, vinyl benzoates, vinyl crotonate, vinyl laurates, vinyl myristate, vinyl linoleate, vinyl linolenate, vinyl cinnamate, vinyl stearates, vinyl oleate, vinyl napthanoates, vinyl cyclopentanoates, vinyl versatates, vinyl salicylate, monovinyl adducts of difunctional or higher functional carboxylic acids such as monovinyl adipate, and the like. Illustrative of the vinyl aromatic, cycloaliphatic, and heterocycles are styrene, vinyl cyclohexane, vinyl cyclopentane, vinyl toluene, vinyl anthracenes, 3-vinyl benzyl chloride, 4-vinyl biphenyl, 4-vinyl-1-cyclohexene, vinyl cyclooctane, 2-vinyl naphthalene, 5-vinyl-2-norbornene, 1-vinyl imidazole, 2-vinyl pyridine, 4-vinyl pyridine, 1-vinyl-2-pyrrolidinone, 9-vinyl carbazole, 3-vinylbenzyl chloride, and the like. The hydroxyalkyl (meth)acrylates and their derivatives include 2-hydroxyethyl acrylate (HEA), hydroxypropyl acrylate (HPA), ethylene oxide and propylene derivatives of HEA and HPA containing from 1 to about 20 moles of the alkylene oxide, caprolactone (meth)acrylates which are epsilon-caprolactone derivatives of HEA and HPA containing from 1 to about 6 moles of epsilon-caprolactone, carboxylic acid terminated adducts of HEA and HPA and the alkylene oxide and caprolactone derivatives of HEA and HPA, and the like. Illustrative of the vinyl halogens and vinylidine halogens are vinyl chloride, vinylidine chloride, vinyl fluoride, vinylidine fluoride, and the like. Illustrative of the alkenes and substituted alkenes are ethylene, propylene, butenes, pentenes, hexenes, heptenes, octenes, nonenes, decenes, 4-chloro-1-butene, 4, 6-dichloro-1-hexene, 5-fluoro-2-hexene, and the like. Illustrative of the nitriles are acrylonitrile, methacrylonitrile, and the like. Illustrative of the vinyl ethers are methyl vinyl ether, ethyl vinyl ether, propyl vinyl ethers, butyl vinyl ethers, pentyl vinyl ethers, hexyl vinyl ethers, hepty vinyl ethers, octyl vinyl ethers, 2-methyl-butyl vinyl ether, and the like.
The polymers are prepared by conventional techniques as exemplified herein and as are known to those skilled in the art of polymerization. The molecular weight of the copolymers making up the polymer particles can vary over wide ranges of average molecular weight and can have number-average molecular weights of from about 1000 to about 1,000,000 or more with a distribution of molecular weights existing. Since film formation of aqueous emulsion polymers conventionally takes place by particle coalescence in which the outer regions of the particles come together and interact to form the final film, it is preferable that the polymer particles of this invention contain a major quantity of the functional groups in, at or near the surface (i.e., the surface region) of the particles, though it is realized that some of the functional groups may be positioned within the interior of the particles. Although the number of copolymers in each polymer particle is indeterminate since particle size and copolymer molecular weight will vary, it is important that, on the average, carboxyl functionality exist on a majority of any copolymer molecules and that at least some of the functionality be found in the surface region or related region so it can react with the post reaction reactants. Other functional groups such as hydroxyl, amine, etc., may also be present in the carboxyl functional polymers, i.e., precursor polymers, used in this invention.
Illustrative of the ethylenically unsaturated carbodiimides, e.g., carbodiimide (meth)acrylates, that can be used for post reaction with the precursor polymer particles to produce the reactive polymers of the invention are the hydrocarbyl carbodiimide (meth)acrylates such as methyl carbodiimide (meth)acrylate, ethyl carbodiimide (meth)acrylate, propyl carbodiimide (meth)acrylates, butyl carbodiimide (meth)acrylates, pentyl carbodiimide (meth)acrylates, hexyl carbodiimide (meth)acrylates, octyl carbodiimide (meth)acrylates, decyl carbodiimide (meth)acrylates, phenyl carbodiimide (meth)acrylate, cyclohexyl carbodiimide (meth)acrylate, methyl phenyl carbodiimide (meth)acrylates, dimethyl phenyl carbodiimide (meth)acrylates; isopropyl, t-butyl, phenyl, and cyclohexyl carbodiimide ethyl (meth)acrylate, carbodiimide di(meth)acrylate, carbodiimide di(ethyl acrylate) carbodiimide di(methyl (meth)acrylate), carbodiimide di(propyl (meth)acrylate)s, carbodiimide di(butyl (meth)acrylate)s, carbodiimide di(hexyl (meth)acrylate)s, carbodiimide di(octyl (meth)acrylate)s, carbodiimide di(cyclohexyl (meth)acrylate)s, and the like. Mixtures of various ethylenically unsaturated carbodiimides may be used for purposes of this invention. Both substituted and unsubstituted ethylenically unsaturated carbodiimides may be used for purposes of this invention.
In an embodiment of this invention, initial aqueous emulsions used to prepare aqueous emulsion polymers of this invention have an initial pH of about 2.0 to 10.5 and contain about 0.05 to 20% or more of carboxylic acid functionality, preferably an initial pH of 3.5 to 9.0 and contain from about 0.1% to 15% carboxylic acid functionality, and are prepared at about 40° C. to about 100° C. for about 6 to 48 hours, preferably at about 60° C. to about 90° C. for about 10 to about 24 hours under atmospheric pressure or superatmospheric pressure of about 15 psig to about 100 psig.
The post reaction leading to the reactive polymers of this invention are carried out at a temperature of from about 0° C. to about 100° C., preferably from about 20° C. to about 90° C., for about 30 minutes to 24 hours or more under atmospheric or superatmospheric pressure of about 15 psig to about 100 psig.
Although not essential, a stoichiometric deficiency of the ethylenically unsaturated carbodiimide may be employed in order to leave some carboxyl functionality in the polymer. Excess carbodiimide is generally avoided since it introduces residual unpolymerized monomer which is undesirable. At least about 0.5% of the ethylenically unsaturated carbodiimide, based on the weight of the polymer, is used. Based on the acid content of the precursor polymer, it is preferred to consume at least 5%, preferably from 10% to about 90%, of the acid (carboxyl) by reaction with the ethylenically unsaturated carbodiimide.
As indicated above, other functional groups such as hydroxyl, amine, etc., may be present in the carboxyl functional polymers, i.e., precursor polymers, used in this invention. Other permissable post reactions may be carried out in a sequential manner so there is no adverse interaction of the reactants used for the post reaction of this invention. Illustrative of other such post reactions include, for example, (1) reaction with an ethylenically unsaturated isocyanate wherein reaction takes place with hydroxyl groups on the precursor polymer particle; (2) reaction with an ethylenically unsaturated isocyanate wherein reaction preferentially takes place with hydroxyl groups on the precursor polymer particle to form free vinyl groups connected to the particle with urethane linkages followed by reaction with an imine to form amine groups on the precursor polymer particle and then with an ethylenically unsaturated isocyanate wherein reaction takes place with the amine groups to form free vinyl groups connected to the particle with urea linkages; (3) reaction with an ethylenically unsaturated isocyanate wherein reaction preferentially takes place with hydroxyl groups on the precursor polymer particle to form free vinyl groups connected to the precursor polymer particle with urethane linkages followed by reaction with an imine to form amine groups on the precursor polymer particle and then with either a mixture or a sequence of glycidyl (meth)acrylate and a carbodiimide (meth)acrylate; and the like. Both substituted and unsubstituted post reactants may be used for purposes of this invention. This invention is not intended to be limited in any manner by the number or combination of permissible post reactions.
The reactive polymers, e.g., aqueous emulsion polymers, of this invention can be used in a variety of ways illustrative of which are as air-dry coatings that will increase in molecular weight presumably through crosslinking by reaction with atmospheric oxygen and/or incidental radiation under ambient conditions without the use of heavy metal catalysts known as drier salts, though such catalysts may be optionally included in coating formulations if desired; as thermally crosslinkable coatings when formulated with peroxides that will break down and cause crosslinking to take place through the ethylenic unsaturation; as radiation curable coatings, preferably in the presence of free-radical generating photoinitiators of either the homolytic fragmentation type or the hydrogen abstraction type which are usually used in combination with a nitrogen-containing synergist when ultraviolet light is used as the radiation source; as solvent reduced coatings in which relatively large quantities of solvent, i.e., more than flexibilizing or plasticizing quantities, are added to the formulation before application to a substrate; and the like.
The reactive polymers of this invention may be used alone or in combination with other systems illustrative of which are aqueous emulsions, water reducible alkyds, solutions of polymers, radiation-curable (meth)acrylates or epoxides, unsaturated fatty acid derivatives, linseed oil, soybean oil, tall oil, and the like. In an embodiment of this invention, aqueous alkyds having molecular weights of from about 500 to 5000 are prepared by adding chain transfer agents to the emulsion polymers during polymerization. In another embodiment of this invention, the reactive polymers of this invention are recovered as a solid, redissolved in an organic solvent, and formulated into solvent-borne coatings, particularly high solids alkyd coatings when low molecular weight polymers are formed in the emulsion process. Suitable solvents are polar in nature illustrative of which are esters, ketones, esters of lactic acid; ethylene oxide glycol ethers as ethylene glycol monomethyl ether, ethylene glycol and diethylene glycol monoethyl ethers, ethylene glycol and diethylene glycol monopropyl ethers, ethylene glycol and diethylene glycol monobutyl ethers, and ethylene glycol and diethylene glycol monohexyl ethers; propylene oxide glycol ethers such as propylene glycol and dipropylene glycol monomethyl ethers, propylene glycol and dipropylene glycol monopropyl ethers, propylene glycol and dipropylene glycol monobutyl ethers, propylene glycol monobutyoxyethyl ether; toluene, methyl ethyl ketone, xylene, dimethylformamide, ethyl acetate, butyl acetate, tetrahydrofuran, 1,1,1-trichloroethane, cyclohexanone, hydroxyethers, and the like. If desired, these solvents may be used in combination with aliphatic hydrocarbons, aromatic hydrocarbons, super critical carbon dioxide. and the like.
When polymers with glass transition temperatures greater than room temperature are formed, film forming agents or plasticizers of various types may be incorporated into the formulations. Such plasticizers may be (1) of a nonreactive nature. illustrative of which are the various esters, ketones, hydroxyethers, and the like which may be fugitive in nature when they have low molecular weight and are lost via evaporation or may be retained by the dry film when they have relatively high molecular weight; (2) of a reactive nature and contain ethylenic unsaturation which reacts with the unsaturation in the polymers of the invention and thus become incorporated into the final film, illustrative of which are diethylene glycol diacrylate, ethylene glycol diacrylate, divinyl adipate, disiopropenyl adipate, divinyl succinate, vinyl crotonate, diallyl phthalate, urethane acrylates, acrylated epoxides, timethylol propane triacrylate, pentaerythritol triacrylate and tetraacrylate, and the like; or (3) a mixture of nonreactive and reactive plasticizers.
Optional heavy metal driers that may be incorporated into the coatings to promote curing. These driers are metal salts of organic acids illustrative of which acids are tall oil fatty acids, ethylhexanoic acid, neodecanoic acids, naphthenic acids, and the like. Illustrative of typical metals used for air- or ambient-dry systems are cobalt, zirconium, and manganese, and the like, and for heat-cure coatings are iron, manganese, cobalt, cerium, and the like. Auxiliary driers include lead, barium, calcium, zirconyl (ZrO--) , zinc, and the like. If desired, mixtures of the various driers can be used.
Illustrative of the peroxides or compounds that will generate oxygen when heated that can be used in the thermally curable coating compositions of this invention are benzoyl peroxide, t-butyl peroxybenzoate, diisopropyl peroxide, and the like. These compounds are used in an amount of about 0.05% to about 5%, preferably from about 0.1% to about 2.5%. It is known to those skilled in the art of these compounds that the cure temperature and decomposition temperature of any chosen compound must be properly considered when they are used.
Illustrative of the homolytic fragmentation-type photoinitiators used in the photocurable coating compositions are 2,2-diethoxyacetophenone, 2,2-dimethoxy-2-phenylacetopheneone, 1-hydroxycyclohexylphenyl ketone, acetophenone, and the like. Illustrative of the hydrogen abstraction-type photoinitiators are benzophenone, benzophenone derivatives, 2-chlorothioxanthone, isopropylthioxanthone, fluorenone, benzil, 9,10-anthraquinone, camphor quinones, 1,3,5-triacetylbenzene, 3-ketocoumarines, acridone, bis-(4,4'-dimethylamino)benzophenone, and the like. Illustrative of the synergists useful in combination with the hydrogen abstraction-type photoinitiators are amine, amides, urethanes or ureas with a hydrogen-bearing carbon atom in the alpha position to the nitrogen group among which one can mention dimethylethanol amine, triethyl amine; primary, secondary, and tertiary amine-terminated poly(propylene oxide) polyols as well urea and urethane derivatives of such polyols, and the like.
Although many of the reactive polymers of this invention can be cured alone with or without added photoinitiator when exposed to ultraviolet light, they may be combined with one or more other radiation-polymerizable ethylenically unsaturated compounds such as substituted or unsubstituted (meth)acrylates. Illustrative of the (meth)acrylates suitable for use in the radiation curable compositions of the invention are the esters of (meth)acrylic acid with monohydric and polyhydric compounds among which one can mention ethyl, butyl, hexyl, octyl, decyl, and the like (meth)acrylates; neopentyl (meth)acrylate, trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate and tetra(meth)acrylate, caprolactone (meth)acrylates which are adducts of 1 to 10 moles of epsilon-caprolactone and a hydroxylalkyl (meth)acrylate, alkoxylated (meth)acrylates, glycerol (meth)acrylates, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropionate di(meth)acrylate, isobornyl (meth)acrylate, tripropylene glycol di(meth)acrylate, unsaturated polyesters, 2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropionate di(meth)acrylates as well as alkoxylated versions of such di(meth)acrylates, urethane (meth)acrylates, (meth)acrylated epoxides, (meth)acrylated linseed oil, (meth)acrylated soybean oil, (meth)acrylated polybutadiene, and the like. In addition, the formulations may contain N-vinyl pyrrolidone, divinylbenzene, and the like.
The reactive polymers, e.g., aqueous emulsions, of this invention can be formulated with a variety of vinyl esters alone or in combination with other radiation-polymerizable ethylenically-unsaturated compounds in the photocurable compositions of this invention. Illustrative of the vinyl esters are vinyl 2-ethylhexanoate. vinyl benzoate, vinyl isovalerate, vinyl nonylates, vinyl neononanoate, vinyl neodecanoate, vinyl myristate, vinyl oleate, vinyl linoleate, vinyl abietate, divinyl adipate, divinyl oxalate. divinyl succinate, divinyl fumarate, divinyl maleate, diisopropenyl adipate, trivinyl mellitate, trivinyl citrate, 1,2,4-trivinyl benzenetricarboxylate, tetravinyl mellophanate, 3,3',4,4'-tetravinyl benzophenonetetracarboxylate, and the like. Such vinyl ester can also be used as reactive flexibizers/plasticizers in other non-photocurable coating compositions of the invention.
The photopolymerization is carried out by exposing the uncured film or coating to light radiation which is rich in short wave radiation. Particularly useful is radiation of about 200 to 450 nanometers in wavelength. Illustrative of appropriate light sources are low-pressure, medium pressure, and high-pressure mercury vapor lamps as well as lamps of this type that have been doped to exclude selected wavelengths; xenon and other flash-type lamps; lasers operating in the above listed wavelength range; sunlight, and the like. Other sources of radiant energy such as electron beams, gamma radiation, X-rays, and so on can also be used.
Any permissible conventional additives, processing aids, etc. may be employed in conventional amounts in the compositions and processes of this invention. This invention is not intended to be limited in any manner by any permissible additives, processing aids, and the like.
The coating compositions of the invention are applied to appropriate substrates as thin films by a variety of processes illustrative of which are roll coating, dip coating, spray coating, brushing, flexographic, lithographic, and offset-web printing processes, and the like.
As used herein, the term "substituted" is contemplated to include all permissible substituents of organic compounds unless otherwise indicated. In a broad aspect, the permissible substituents include acyclic and cyclic, branched and unbranched, carbocyclic and heterocyclic, aromatic and nonaromatic substituents of organic compounds. Illustrative substituents include, for example, alkyl, alkyloxy, aryl, aryloxy, hydroxy, hydroxyalkyl, amino, aminoalkyl, halogen and the like in which the number of carbons can range from 1 to about 20 or more, preferably from 1 to about 12. The permissible substituents can be one or more and the same or different for appropriate organic compounds. This invention is not intended to be limited in any manner by the permissible substituents of organic compounds.
The invention is illustrated by certain of the following examples.
Glossary of Terms and Compound
Gel Fraction--The gel fraction or gel content is the amount of material that is insoluble when a given mass of the cured coating is extracted with tetrahydrofuran (THF) for 18 hours at room temperature. The extracted film is removed from the THF, rinsed with fresh THF, and dried at 110° C. for one hour. The gel fraction, expressed as a percentage, is calculated with the following expression.
Gel Fraction=(1-((Weight of original film-Weight extracted film)/(Weight of original film))×(100%)
Gloss, 60° --ASTM D 523
Yellowness Index--ASTM D 1925
Pencil Scratch Hardness--ASTM D 3363
Crosshatch Adhesion--ASTM D 3359
Acetone Double Rubs are a measure of the resistance of the cured film to attack by acetone in which test a film coating surface was rubbed with an acetone-soaked cloth back and forth with hand pressure. A rub back and forth over the film coating surface with the acetone soaked cloth, which is usually a nonwoven type cloth material, was designated as one "double acetone rub,." The number of double rubs given as a value is the number of double rubs after which the film is noticeably affected by the action.
Water Spot Test--ASTM D-2247
Alkyd 1--A water reducible, styrenated alkyd resin commercially available from Cargill.
Photoinitiator I--A free-radical generating photoinitiator commercially available from Ciba-Geigy Corporation as Irgacure®b 651.
Surfactant 1--A sodium dioctyl sulfosuccinate anionic surfactant commercially available from American Cyanamid Company under the designation Aerosol® OT-75.
Surfactant 2--A 70% solution of nonyl phenol-based alkylene oxide nonionic surfactant in water commercially available from Union Carbide Chemicals and Plastics Company Inc. under the designation Tergitol® NP-40.
Surfactant 3--A nonyl phenol-based alkylene oxide nonionic surfactant commercially available from Union Carbide Chemicals and Plastics Company Inc. under the designation Tergitol® NP-15.
Surfactant 4--A sodium dodecyl benzyl sulfonate anionic surfactant commercially available from WITCO Corporation under the designation Witconate® (W1233H.
Surfactant 5--A fluorochemical surfactant commercially available from 3M Company under the designation FC-430.
EXAMPLES
Preparation A
Preparation of cyclohexyl carbodiimide ethyl methacrylate
Step 1. Preparation of a urea methacrylate solution. To a five-liter, three-neck, round bottom, glass reaction flask equipped with a mechanical stirrer, thermometer, and feed tank, 1,500 grams of methylene chloride solvent and 356.8 grams of isocyanato ethyl methacrylate reactant were added and cooled to 5° C. A mixture of 228.1 grams of cyclohexyl amine and 199 grams of methylene chloride were added to the feed tank over a two-hour period at such a rate that the temperature was maintained between 2° C. and 13° C. Agitation was supplied during the entire reaction period. When the cyclohexyl amine addition was complete, 0.05 grams of 2,6-di-tert-butyl-4-methylphenol stabilizer was added, and the agitated contents of the reactor were maintained at 14° C. for 16 hours. The resulting urea methacrylate solution was stored at room temperature for future use.
Step 2. Preparation of cyclohexyl carbodiimide ethyl methacrylate. Seven liters of methylene chloride were added to a 12-liter, jacketed glass reaction flask equipped with a mechanical stirrer, a nitrogen purge tube, thermometer, and feed tank. The methylene chloride was cooled to 6° C. and then 720.8 grams of triphenyl phosphine were added. A nitrogen sparge was begun and a mixture of 439.1 grams of bromine and 200 millileters of methylene chloride were fed to the reactor by means of the feed tank to form a solution of triphenyl phosphine dibromide in the reactor. Then a mixture of 562.2 grams of triethyl amine and 150 milliliters of methylene chloride were fed to the reactor by means of the feed tank. During the additions of reactants, the temperature was maintained below 15° C. Then, the stored urea methacrylate of Step 1 was placed in the feed tank and fed to the solution of triphenyl phosphine dibromide and triethyl amine over a 2.5 hour time period at a rate so as to keep the reaction temperature below 11° C. After addition of the Step 1 product was complete, the reaction mixture was stirred overnight at room temperature to complete the reaction to the cyclohexyl carbodiimide ethyl methacrylate.
The next morning, the reaction mixture was washed five time with 760 milliliters portions of water. The organic solution was then dried with 4A molecular sieves. The methylene chloride was then remove from the reaction mixture by means of a roto-evaporator. A total of 1,289 grams of crude, solvent-free reaction product was obtained. Cyclohexyl carbodiimide ethyl methacrylate was extracted from the crude reaction product by three successive additions of 800 milliliters aliquots of hexane. Hexane was removed from the crude carbodiimide methacrylate by means of a roto-evaporator. The yield of crude carbodiimide was 480 grams, which was purified by distillation in a Kontes' Falling Film Molecular Still. Yield of the 96of pure desired cyclohexyl carbodiimide ethyl methacrylate product with a molecular mass of 236 was 74% with purity determined by gas chromatography, infrared analysis of the --N═C═N--band at 2120 cm-1 as well as other characteristic bands from both infrared and NMR analysis. The product had a density of 1.020 grams/milliliters (25° C.) and a refractive index of 1.4911 (24.8° C.) and was stored for future use.
Preparations B,C and D
Preparation of various carbodiimide ethyl methacrylates.
The carbodiimide methacrylates described in Table 1 were prepared in the same manner as described for Preparation A except that the indicated amine was substituted for the cyclohexyl amine used in Step 1 of Preparation A.
TABLE 1__________________________________________________________________________Prep- Amine Density Refractivearation Used Product Formed Purity (25° C.) Index (24.8° C.)__________________________________________________________________________B t-butyl t-butyl carbodiimide 100 0.964 1.4619 ethyl methacrylateC i-propyl i-propyl carbodiimide 99.3 0.982 1.4685 ethyl methacrylateD analine phenyl carbodiimide 96.4 1.0893 1.5501 ethyl methacrylate__________________________________________________________________________
Preparation E
Preparation of a carbodiimide dimethacrylate
Step 1. Preparation of a urea methacrylate solution. To a 500 milliliter, three-neck, round bottom, glass reaction flask equipped with a mechanical stirrer, thermometer, condenser, and a nitrogen purge, 120 grams of methyl Propasol® acetate, 40.45 grams of 2-hydroxyethyl methacrylate, and 2.0 grams of 2,3-di-tert-butyl-4-methylphenol were added. The stirred solution cooled to 0° C., and 69.07 grams of isophorone diisocyanate were added. Stirring was continued for the remainder of the reaction period. This mixture was heated to 90° C. and held at temperature for three hours at which time an addition 12.13 grams of 2-hydroxyethyl methacrylate were added. Heating was continued at 90° C. for 2.3 hours. Then, the reaction temperature was increased to 145° C. and 30 grams of a 10% solution of 3-methyl-1-phenyl-2-phospholene-1-oxide in xylenes were added. The reaction temperature was maintained at 145° C. for eight hours after which time the carbodiimide methacrylate was covered in the same manner as described in Preparation A. Infrared and NMR analysis indicated the final product was a mixture that contained 32.9% of a carbodiimide dimethacrylate (molecular mass 660.4), 17.2% of a dicarbodiimide dimethacrylate (molecular mass 838.6), 42.5% of a dimethacrylate (molecular mass 482.3), and 4.1% of a 352.2 molecular mass compound. Molecular masses and weight percentages were determined by mass spectroscopy and gel permeation chromatography using polystyrene standards.
Preparation F
Preparation of aqueous emulsion polymer
A monomer solution mixture composed of the compounds in Table 2 was prepared.
TABLE 2______________________________________Monomer Grams Used Wt. % of Mixture______________________________________Methyl methacrylate 450.0 44.2Styrene 200.0 19.7n-Butyl methacrylate 250.0 24.6Methacrylic acid 100.0 9.8Mercaptoacetic acid 17.2 1.7______________________________________
A glass resin kettle equipped for temperature control and agitation was charged with 1,100.0 grams of deionized water, 0.34 gram of Surfactant 1, 1.30 grams of Surfactant 2, and 50 grams of the monomer solution. A nitrogen purge was started in the reaction mixture, and the contents of the resin kettle were increased to 85° C. at which point an initiator mixture consisting of 5.6 grams of ammonium persulfate dissolved in 147 grams of deionized water were added to the kettle and the temperature was set and maintained at 80° C. The remainder of the monomer solution was then fed to the reactor over a period of 225 minutes. Five minutes after the monomer feed was started, an initiator feed composed of 4.2 grams of ammonium persulfate dissolved in 107.8 grams of deionized water was started and fed to the reactor over a time period of 240 minutes. Fifteen minutes after the initiator feed was completed, a post initiator solution composed of 0.3 grams of ammonium persulfate and 0.3 grams of sodium metabisulfite dissolved in 49.4 grams of water was added over a time period of 30 minutes. After the final addition of reaction material, the aqueous emulsion of polymer was kept at the 80° C. reaction temperature for an additional 30 minutes. Analysis indicated that the emulsion had a pH of 2.25, a Brookfield viscosity of 7.1 centipose (LVT #1 at 60 rpm). There was a 96.1% conversion of monomer, polymer or solids content was 40.66%, and the polymer had a Mn of 10,800 and a Mw of 26,800 grams/mole.
EXAMPLE 1
Modification of Preparation F aqueous emulsion
Step 1. An emulsion of the Preparation A cyclohexyl carbodiimide ethyl methacrylate was prepared by first adding 0.28 grams of ammonium hydroxide to 28.8 grams of deionized water in a glass container and then adding 17.2 grams of Preparation A methacrylate and 0.288 grams of Surfactant 2 to the mixture. The mixture of compounds was agitated to effect emulsification.
Step 2. To a three-necked, round-bottomed glass reaction flask equipped with a condenser, mechanical stirrer, and thermometer 150 grams of Preparation F aqueous emulsion were added. While stirring the emulsion, 1.5 grams of Surfactant 2 were added and the pH of the emulsion was adjusted to 8.5 with a 14% aqueous solution of ammonium hydroxide. After 40 minutes, the pH was redetermined and found to be unchanged at 8.5. Then, the Step 1 emulsion was added and the mixture was stirred for 30 minutes. The temperature was increased to 80° C. and held at this temperature for 22 hours. Gas chromatography confirmed the reaction of carbodiimide groups and carboxyl groups had reached completion. The aqueous emulsion polymer had a final pH of 6.1. An additional 1.5 grams of Surfactant 1 and 0.38 grams of Foamaster® (Henkel) were added to the final emulsion before storage for future use for characterization.
Twenty grams of the reactive polymer of Example 1 were air dried (indicating no gel fraction), dissolved in tetrahydrofuran, and then precipitated in water. The resultant polymer with pendant unsaturation provided by the free acrylate groups was filtered and then vacuum dried at 60° C. overnight. Titration for free carboxylic add moieties on the polymer indicated that 95% of these groups had been consumed as a result of modification with the carbodiimide of Preparation A. NMR analysis of the dried polymer indicated that it contained 95% of the theoretical amount of ethylenic unsaturation that should exist in the form of methacrylate groups.
EXAMPLES 2-7 AND CONTROLS I-VI
Evaluation of aqueous emulsion polymers
To 6.31 gram portions of the Example 1 aqueous emulsion polymer product, 5 parts of t-butyl peroxybenzoate were added per 100 parts of the product. To these mixtures, the reactive filming aid in the amount indicated in Table 3 was added. The ingredients were stirred for 30 minutes or more and then oven cured in aluminum dishes at the indicated temperatures for 30 minutes. After the samples cooled to room temperature, 50 milligram samples of each were removed from the pans and gel fraction was determined as a percentage and is given in Table 3.
TABLE 3__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExampleFilming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________2 None -- 48.37 69.61 78.04 85.913 1,1,1-Trimethyol propane triacrylate 3.0 57.87 74.64 79.34 85.454 1,1,1-Trimethyol propane triacrylate 7.0 45.90 72.59 80.67 87.285 Diethylene glycol dimethacrylate 7.0 50.98 69.17 78.93 85.566 Pentaerythritol triacrylate 7.0 38.15 66.91 79.31 87.367 Pentaerythritol tetraacrylate 7.0 39.20 63.16 76.74 88.30__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
The moderate to high gel content for all samples, including those without reactive plasticizer, indicates that when the emulsion polymers are heated alone or with acrylates that contain ethylenic unsaturation in combination with oxygen-producing compounds, they undergo significant insolublization. To demonstrate the difference modification of the aqueous emulsion product makes on cure properties, the original Preparation F aqueous emulsion used to make Example 1 product was formulated and cured in the same way as described above. The gel fraction, expressed as a percentage, results given in Table 4, show that the aqueous emulsion polymer products of this invention (Table 3 results) undergo greater insolublization than the unmodified aqueous emulsion polymer products. Insignificant insolubilization took place when the Preparation F product was heated without added acrylate.
TABLE 4__________________________________________________________________________ Percent Gel Fraction Amount TemperatureControlsFilming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________I None -- 0.76 0.39 0.57 0.75II 1,1,1-Trimethyol propane triacrylate 3.0 1.96 1.38 0.990 0.36III 1,1,1-Trimethyol propane triacrylate 7.0 5.14 6.60 7.39 9.62IV Diethylene glycol dimethacrylate 7.0 5.76 5.92 6.08 7.27V Pentaerythritol triacrylate 7.0 4.90 8.37 11.43 10.48VI Pentaerythritol teraacrylate 7.0 5.09 5.26 5.19 7.28__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
EXAMPLE 8-11
Evaluation of aqueous emulsion polymers
To 12.0 gram portions of the Example 1 emulsion product, the ingredients given in Table 5 were added and the mixtures were stirred for 30 minutes. The formulations were coated onto Bonderite cold-rolled steel panels with a draw-down rod to yield 10-mil wet coatings which were thermally cured in a forced-air oven at 160° C. Properties of the cured coatings are given in Table 5.
TABLE 5______________________________________ Examples 8 9 10 11______________________________________Ingredients, gramsExample 1 emulsion product 12.0 12.0 12.0 12.0t-Butyl peroxybenzoate -- 0.23 0.23 0.23Trimethylol propane -- -- 0.32 --triacrylatePentraerythritol triacrylate -- -- -- 0.32Cured Film PropertiesThickness, mils 1.2 1.3 1.4 1.9Gloss, 60° 29 97 91 89Yellowness Index 26.5 23.7 30 23.1Pencil Scratch Hardness 4H 2H 2H 4HCrosshatch Adhesion 1B -- 2B 2BAcetone Double Rubs 100 100+ 100+ 100+Water Spot Test Passed Passed Passed Passed______________________________________
The properties obtained with the emulsion polymers when heated alone or with acrylates that contain ethylenic unsaturation in combination with or without oxygen-producing compounds, indicate that a variety of useful coating properties result.
EXAMPLES 12-14
Evaluation of Aqueous emulsion polymers
The formulations indicated in Table 6 were stirred for 30 minutes and then coated by the draw-down technique onto cold-rolled steel panels to form a 10 mil wet coating. The coatings were exposed to the ultraviolet light from a 300 watt-per-inch, medium-pressure mercury vapor lamp for 14 seconds. After ultraviolet light exposure the gel fraction content was determined and is reported as a percentage in Table 6. The results indicate that insolubilization took place under the conditions of ultraviolet light exposure.
TABLE 6______________________________________ ExamplesIngredients, grams 12 13 14______________________________________Example 1 emulsion product 5.0 10.0 10.0Photoinitiator I 0.08 0.16 0.16Trimethylol propane triacrylate -- 0.27 --Pentaerythritol triacrylate -- -- 0.27Surfactant 5 1 Drop 1 Drop 1 DropGel Fraction, % 41.0 36.5 26.6______________________________________
PREPARATION G
Preparation Of aqueous emulsion polymer
A monomer solution mixture composed of the compounds in Table 7 was prepared.
TABLE 7______________________________________Monomer Grams Used Wt. % of Mixture______________________________________Vinyl acetate 750.0 74.56Vinyl 2-ethyl hexanoate 189.57 18.82Methyl methacrylate 7.20 0.71Monovinyl adipate 60.43 6.00______________________________________
A glass resin kettle equipped for temperature control, a means of introducing reactants, and agitation was charged with 765.56 grams of deionized water, 1.22 grams of aqueous, 0.02% ferric chloride solution, 25.8 grams of Surfactant 2, 6.00 grams of Surfactant 3, 13.00 grams of Surfactant 4, 4.0 grams of hydroxyethyl cellulose (WP-300, Union Carbide Chemical and Plastics Company Inc.), 4.00 grams sodium vinyl sulfonate, and 2.00 grams sodium acetate. A nitrogen purge was started in the reaction mixture, and the contents of the resin kettle were increased to 65° C. at which point two catalyst feeds were started. One feed consisted of 0.64 gram of sodium vinyl sulfonate dissolved in 60.0 grams of water and the other feed was composed of 0.64 gram of t-butyl hydroperoxide dissolved in 60.0 grams of water. These were fed to the reactor over a 250-minute time period. Ten minutes after the two catalyst feeds were started, the monomer solution was fed to the reactor over a period of 180 minutes. After completion of the monomer feed, the temperature was increased to 75° C. and the reactants were kept at this temperature for 1 hour. Analysis indicated that conversion was 99% and the solids content of the aqueous emulsion was 52.95%.
EXAMPLE 1
Modification of Preparation G aqueous emulsion
Step 1. An emulsion of the Preparation A cyclohexyl carbodiimide ethyl methacrylate was prepared by first adding 0.2 grams of ammonium hydroxide to 80 grams of deionized water in a glass container and then adding 13.1 grams of Preparation A methacrylate and 0.5 gram of Surfactant 2 to the mixture. The mixture of compounds was agitated to effect emulsification.
Step 2. To a three-necked, round-bottomed glass reaction flask equipped with a condenser, mechanical stirrer, and thermometer 300 grams of Preparation G aqueous emulsion were added. While stirring the emulsion, 3.0 grams Surfactant 2 were added, and the pH of the emulsion was adjusted to 7.8 with a 14% aqueous solution of ammonium hydroxide. After 1 hour, the pH was readjusted to 7.8. Then, the Step 1 emulsion was added and the mixture of aqueous emulsions was stirred for 30 minutes. The temperature was increased to 80° C. and held at this temperature for 3 hours. Then 0.68 gram of Foamaster® VF (Henkel) was added the stirring was continued for 30 minutes. The final aqueous emulsion of ethylenically unsaturated, nitrogen-containing polymer had a pH of 7.7 and a solids content of 41.8%. When one gram of the emulsion was added to 20 milliliters of tetrahydrofuran, a clear solution resulted.
EXAMPLES 16-18
Evaluation of aqueuous emulusion polymers
Samples of the Example 15 aqueous emulsion were formulated and cured as in the same manner described for Examples 2-7. After the samples cooled to room temperature, 50 milligram samples of each were removed from the pans and gel fraction was determined as a percentage and is given in Table 8.
TABLE 8__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesFilming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________16 None -- 79.68 83.04 88.06 88.0317 1,1,1-Trimethyol propane triacrylate 3.0 77.20 90.14 92.84 91.8518 1,1,1-Trimethyol propane triacrylate 7.0 85.26 91.16 92.41 95.26__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
The results indicate that a high degree of insolubilization was obtained for all samples.
EXAMPLES 19-23
Evaluation of aqueous emulsion polymers
Samples of the Example 15 aqueous emulsion were formulated in the manner described in Examples 2-7 except that diallyl phthalate was used as the reactive filming aid. Before stirring, drier salts were added to some of the examples as indicated in Table 9. The films were allowed to air cure under ambient conditions for 12 days after which gel content was determined. Gel fraction was determined as a percentage and is given in Table 9. The results indicate that significant gel contents are obtained with and without added drier salts.
TABLE 9______________________________________Ingredients, Examplesparts by weight 19 20 21 22 23______________________________________Example 15 emulsion 100 100 100 100 100productDiallyl phthalate -- 5 -- 5 5Cobalt 2-ethyl- -- -- 1 1 0.6hexanoateZirconium octoate -- -- -- -- 0.6Gel Fraction, % 57.8 54.3 40.2 57.5 49.4______________________________________
The film prepared in Example 19 had a thickness of 1.4 mil, a 60° gloss of 76, a crosshatch adhesive value of 5B, a pencil hardness of HB, and 40 acetone double rubs cut through the film.
EXAMPLES 24-31
Modification of aqueous emulsion polymer
A water dispersed master batch, designated as Batch 1 Alkyd (containing Alkyd 1) was prepared by adding 12 grams of ammonium hydroxide to 52 grams of deionized water and then dispersing 292 grams of Alkyd 1 in the solution by stirring. To 20 grams of Example 15 aqueous emulsion, the drier salts and Batch 1 Alkyd in the amounts indicated in Table 10 were added and the ingredients were stirred for 30 minutes to form water dispersed alkyd. The coatings were applied to Bonderite cold rolled steel panels with the draw down technique to form 10-mil wet films. The films were allowed to cure for 2 days under ambient conditions except for Example 24 which was cured 12 days.
TABLE 10__________________________________________________________________________ ExamplesAdded Ingredients, grams 24 25 26 27 28 29 30 31__________________________________________________________________________Drier saltsCobalt octoate -- -- 0.042 0.084 -- 0.42 0.084 0.042Zirconium octoate -- -- 0.042 0.084 -- 0.42 0.084 0.042Batch 1 alkyd -- 2.5 0.6 0.6 2.5 0.6 0.6 2.5Cured Film PropertiesGel Fraction, % 57.8 50.6 64.0 54.8 30.3 70.7 56.2 73.3Film Thickness 1.4 1.5 1.3 -- 2.2 2.5 2.4 1.9Gloss, 60° 76 53 44 -- 40 20 16 34Acetone Double Rubs 40 42 30 -- 50 70 90 100+Crosshatch Adhesion 5B 1B 4B -- 4B 4B 5B 5BPencil Hardness HB HB B -- 3B 3B 3B 3B__________________________________________________________________________
The results indicate that alkyds can be used to modify the aqueous emulsion polymers of the invention. Significant gel contents as well as good coating properties are obtained with or without the use of drier salts.
EXAMPLE 32
Modification of Preparation F aqueous emulsion
Step 1. An emulsion of the Preparation B t-butyl carbodiimide ethyl methacrylate was prepared by first adding 0.56 gram of ammonium hydroxide to 60 grams of deionized water in a glass container and then adding 30.6 grams of Preparation B methacrylate and 0.600 gram of Surfactant 2 to the mixture. The mixture of compounds was agitated to effect emulsification.
Step 2. To a three-neck, round-bottom, glass reaction flask equipped with a condenser, mechanical stirrer, and thermometer 300 grams of Preparation F aqueous emulsion were added. While stirring the emulsion, 3.0 grams of Surfactant 2 were added and the pH of the emulsion was adjusted to 8.5 with a 14% aqueous solution of ammonium hydroxide. After 40 minutes, the pH was redetermined and found to be unchanged at 8.5. Then, the Step 1 emulsion was added and the mixture was stirred for 30 minutes after which time the temperature was increased to 80° C. and the reaction mass was held at this temperature for 22 hours. Gas chromatography and infrared analyses confirmed the reaction of carbodiimide groups and carboxyl groups had reached completion after this time. Then, 0.68 grams of Foamaster® VF (Henkel) were added and stirring was continued for 30 minutes. Final emulsion pH was 7.0 and solids content was 35.7%. The emulsion was stored for future use. Twenty grams of the above aqueous emulsion polymer were air dried, dissolved in tetrahydrofuran, and then precipitated in water. The resultant polymer with pendant unsaturation provided by the free acrylate groups was filtered and then vacuum dried at 60° C. overnight. Titration for free carboxylic acid moieties on the polymer indicated that 66% of these groups had been consumed as a result of modification with the carbodiimide of Preparation B. NMR analysis of the dried polymer indicated that it contained 76% of the theoretical amount of ethylenic unsaturation that should exit in the form of methacrylate groups.
EXAMPLES 33-38
Evaluation of aqueous emulsion polymers
To 6.31 grams portions of the Example 32 emulsion product, 5 parts of t-butyl peroxybenzoate were added per 100 parts of the Example 32 product. To these mixtures, the reactive filming aid in the amount indicated in Table 11 was added. The ingredients were stirred for 30 minutes or more and then oven cured in aluminum dishes at the indicated temperatures for 30 minutes. After the samples cooled to room temperature, 50 milligram samples of each were removed from the pans and gel fraction was determined as a percentage and is given in Table 11.
TABLE 11__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesFilming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________33 None -- 55.51 58.14 60.89 84.7934 1,1,1-Trimethyol propane triacrylate 3.0 53.17 65.77 74.32 85.5535 1,1,1-Trimethyol propane triacrylate 7.0 57.84 60.53 72.49 88.1836 Diethylene glycol dimethacrylate 7.0 63.61 69.33 76.03 84.7537 Pentaerythritol triacrylate 7.0 62.43 66.14 71.18 87.4138 Pentaerythritol tetraacrylate 7.0 53.66 61.30 72.34 86.65__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
The high gel fractions for all samples, including those without reactive plasticizer, indicates that when the emulsion polymers are heated alone or with filming aids that contain ethylenic unsaturation in combination with oxygen-producing compounds, they undergo significant insolublization.
EXAMPLES 39-42
Evaluation of aqueous polymer emulsions
To 15.0 gram portions of the Example 32 emulsion product, the ingredients given in Table 12 were added and the mixtures were stirred for 30 minutes. The formulations were coated onto Bonderite cold-rolled steel panels with a draw-down rod to yield 10-rail wet coatings which were thermally cured in a forced-air oven at 160° C. Properties of the cured coatings are given in Table 12.
TABLE 12______________________________________ Examples 39 40 41 42______________________________________Ingredients, gramsExample 32 product 15.0 15.0 15.0 15.0t-Butyl peroxybenzoate -- 0.27 0.27 0.27Trimethylol propane -- -- 0.38 --triacrylatePentraerythritol triacrylate -- -- -- 0.38Cured Film PropertiesThickness, mils 1.4 1.8 1.6 1.5Gloss, 60° 52 96 98 86Yellowness Index 9.9 4.5 2.9 12.5Pencil Scratch Hardness 3H 3H 3H HAcetone Double Rubs 35 70 80 50Water Spot Test Failed Passed Failed Passed______________________________________
The properties obtained with the emulsion polymers when heated alone or with multifunctional acrylates that contain ethylenic unsaturation in combination with or without oxygen-producing compounds, indicate that a variety of useful coating properties result.
EXAMPLES 43-46
Evaluation of aqueous emulsion polymers
The formulations indicated in Table 13 were stirred for 30 minutes and then coated by the draw-down technique onto Bonderite cold-rolled steel panels to form a 10-mil wet coating. The coatings were exposed to the ultraviolet light from a 300 watt-per-inch, medium-pressure mercury vapor lamp for 14 seconds. After ultraviolet light exposure the gel fraction content was determined and is reported as a percentage in Table 13. The gel fraction results indicate that insolublization took place under the conditions of ultraviolet light exposure and the coating-test properties indicate that a useful coating can be made from the compositions of this invention.
TABLE 13______________________________________ Examples 43 44 45 46______________________________________Ingredients, gramsExample 31 product 20.0 20.0 20.0 20.0Photoinitiator 1 -- 0.21 0.21 0.21Trimethylol propane -- -- 0.50 --triacrylatePentaerythritol triacrylate -- -- -- 0.50Surfactant 5 1 Drop 1 Drop 1 Drop 1 DropGel Fraction, % 18 79 83 84Cured Film PropertiesThickness, mils 1.8 3.2 1.6 0.4Gloss, 60° 25 19 77 73Yellowness Index 2.9 8.6 18.5 10.0Pencil Scratch Hardness -- 2H 2H 3HAcetone Double Rubs 48 100+ 100+ 100+______________________________________
EXAMPLE 47
Modification of Preparation F aqueous emulsion
Step 1. An emulsion of triethylamine was prepared by placing 28.8 grams of deionized water and 11.52 grams of triethyl amine in a glass container and then adding 0.288 gram of Surfactant 2 to the mixture. The blend of compounds was agitated to effect emulsification.
Step 2. An emulsion of the Preparation B t-butyl carbodiimide ethyl methacrylate was prepared by first placing 28.8 grams of deionized water, 0.288 gram of triethylamine, 0.288 gram of Surfactant 2, and 15.5 grams of Preparation B carbodiimide methacrylate in a glass container and agitating the compounds to effect emulsification.
Step 3. To a three-neck, round-bottom, glass reaction flask equipped with a condenser, mechanical stirrer, and thermometer 150 grams of Preparation F aqueous emulsion were added. While stirring the emulsion, 1.48 grams of Surfactant 2 were added and the pH of the emulsion was adjusted to 7.5 with the Step 1 triethylamine emulsion. After 18 hours, the pH was adjusted from 7.0 to 7.5 with the Step 1 emulsion. Then, the Step 2 emulsion was added and the mixture was stirred for 30 minutes after which time the temperature was increased to 80° C. and the reaction mass was held at this temperature for 22 hours. Previous gas chromatography and infrared analyses had confirmed that the reaction of carbodiimide groups and carboxyl groups had reached completion after this time. Final emulsion of the aqueous emulsion had a solids content of 38.4%. The emulsion, which was soluble in tetrahydrofuran, was stored for future use. Twenty grams of the above aqueous emulsion polymer were air dried, dissolved in tetrahydrofuran, and then precipitated in water. The resultant polymer with pendant unsaturation provided by the free acrylate groups was filtered and then vacuum dried at 60° C. overnight. NMR analysis of the dried polymer indicated that it contained 65% of the theoretical amount of ethylenic unsaturation that should exit in the form of methacrylate groups.
EXAMPLES 48-50
Evaluation of aqueous polymer emulsions
To 6.31 gram portions of the Example 47 emulsion product, 5 parts of t-butyl peroxybenzoate were added per 100 parts of the Example 47 product. To these mixtures, the reactive filming aid in the amount indicated in Table 14 was added. The ingredients were stirred for 30 minutes or more and then oven cured in aluminum dishes at the indicated temperatures for 30 minutes. After the samples cooled to room temperature, 50 milligram samples of each were removed from the pans and gel fraction was determined as a percentage and is given in Table 14. The results indicate that significant amounts of the copolymers are insolubilized.
TABLE 14__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesReactive Filming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________48 None -- 33.95 49.27 54.96 62.4849 1,1,1-Trimethyol propane triacrylate 3.0 49.22 49.91 65.91 75.0550 1,1,1-Trimethyol propane triacrylate 7.0 40.82 48.95 59.88 72.72__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
EXAMPLE 51
Modification of Preparation F aqueous emulsion
In the same manner as described in Example 1, Preparation F was modified with a carbodiimide methacrylate except 14.66 grams of isopropyl carbodiimide ethyl methacrylate Preparation C were substituted for the cyclohexyl carbodiimide ethyl methacrylate. The final emulsion had a solids content of 40.3%. Twenty grams of the resulting emulsion polymer was dissolved in tetrahydrofuran, precipitated with water, filtered, and vacuum dried at 60° C. overnight. Nuclear magnetic resonance analysis of the dried polymer indicated the copolymer contained 55.8% of the theoretical amount.
EXAMPLES 52-54
Evaluation of aqueous polymer emulsions
Formulations were prepared in the same manner as described in Examples 48-50 using the reactive filming aid in the amount indicated in Table 15. The cured formulations were analyzed for gel fraction. The results indicated that the cured formulations contained large amounts of insoluble material indicating good solvent resistance properties.
TABLE 15__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesReactive Filming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________52 None -- 60.48 68.50 77.49 83.7953 1,1,1-Trimethyol propane triacrylate 3.0 63.55 73.42 81.77 87.1354 1,1,1-Trimethyol propane triacrylate 7.0 60.63 74.66 77.55 92.52__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
EXAMPLE 55
Modification of Preparation F aqueous emulsion
In the same manner as described in Example 1, Preparation F was modified with a carbodiimide methacrylate except 17.2 grams of phenyl carbodiimide ethyl methacrylate Preparation D was substituted for the cyclohexyl carbodiimide ethyl methacrylate. The final emulsion had a solids content of 40.3%. Twenty grams of the resulting emulsion polymer was dissolved in tetrahydrofuran, precipitated with water, filtered, and vacuum dried at 60° C. overnight. Nuclear magnetic resonance analysis of the dried polymer indicated the copolymer contained 59% of the theoretical amount.
EXAMPLES 56-58
Evaluation of aqueous polymer emulsions
Formulations were prepared in the same manner as described in Examples 48-50 using the reactive filming aid in the amount indicated in Table 16. The cured formulations were analyzed for gel fraction. The results indicated that the cured formulations contained significant amounts of insoluble material suggesting that coatings prepared from them would have good solvent resistance properties.
TABLE 16__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesReactive Filming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________56 None -- 12.09 19.63 26.82 29.3157 1,1,1-Trimethyol propane triacrylate 3.0 17.74 32.43 36.95 40.4258 1,1,1-Trimethyol propane triacrylate 7.0 28.31 43.67 43.57 49.27__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
EXAMPLE 59
Modification of Preparation F aqueous emulsion
To a three-necked, round-bottomed glass reaction flask equipped with a condenser, mechanical stirrer, and thermometer 150 grams of Preparation F aqueous emulsion were added. While stirring the emulsion, 1.5 grams of Surfactant 2 were added and the pH of the emulsion was adjusted to 8.5 with a 14% aqueous solution of ammonium hydroxide. At this point, 40 grams of deionized water were added. After 30 minutes, the pH was adjusted to 8.5 with the ammonium hydroxide solution. Then, the 39.9 grams of Preparation E carbodiimide dimethacrylate containing 1% Surfactant 1 and 2% Surfactant 2 were added. The emulsion was stirred for 18 hours at room temperature and then the temperature was increased to 80° C. and maintained at this temperature with stirring for 22 hours. The final emulsion had a pH of 6.8 and a solids content of 42.8%. Twenty grams of the emulsion was air dried, dissolved in tetrahydrofuran, precipitated in water, filtered, and vacuum dried at 60° C. overnight. Titration of the carboxylic acid groups on the polymer indicated that 87% of these groups had been reacted with Preparation E carbodiimide dimethacrylate.
EXAMPLE 60-62
Evaluation Of aqueous polymer emulsions
Formulations were prepared in the same manner as described in Examples 48-50 using the reactive filming aid in the amount indicated in Table 17. The cured formulations were analyzed for gel fraction. The results indicated that the cured formulations contained large amounts of insoluble material suggesting that coatings prepared from them would have good solvent resistance properties.
TABLE 17__________________________________________________________________________ Percent Gel Fraction Amount TemperatureExamplesReactive Filming Aid phr* 120° C. 130° C. 140° C. 160° C.__________________________________________________________________________60 None -- 31.84 32.16 45.23 55.9661 1,1,1-Trimethyol propane triacrylate 3.0 28.20 32.76 51.09 59.6262 1,1,1-Trimethyol propane triacrylate 7.0 23.01 45.83 50.96 67.76__________________________________________________________________________ *phr = parts per hundred parts, i.e., parts of filming aid per 100 parts of mixture.
EXAMPLES 63-66
Evaluation of aqueous polymer emulsions
Thermal-cure evaluation of coatings prepared from the Example 59 emulsion product alone and in combination with acrylates. To 15.0 gram portions of the Example 59 product, the ingredients given in Table 18 were added and the mixtures were stirred for 30 minutes. The formulations were coated onto Bonderite cold-rolled steel panels with a draw-down rod to yield 10-mil wet coatings which were thermally cured in a forced-air oven at 160° C. Properties of the cured coatings are given in Table 18.
TABLE 18______________________________________ Examples 63 64 65 66______________________________________Ingredients, gramsExample 59 emulsion product 15.0 15.0 15.0 20.0t-Butyl peroxybenzoate -- 0.32 0.32 0.43Trimethylol propane -- -- 0.44 --triacrylatePentraerythritol triacrylate -- -- -- 0.60Cured Film PropertiesThickness, mils 2.2 1.9 1.9 2.0Gloss, 60° 89 94 92 78Yellowness Index 4.8 5.9 6.6 17.9Pencil Scratch Hardness HB HB F FAcetone Double Rubs 40 30 50 70Water Spot Test Passed Passed Passed Passed______________________________________
The properties obtained with the emulsion polymers when heated alone or with multifunctional acrylates that contain ethylenic unsaturation in combination with or without oxygen-producing compounds, indicate that a variety of useful coating properties result.
EXAMPLES 67-70
Evaluation of aqueous polymer emulsions
The formulations indicated in Table 19 were stirred for 30 minutes and then coated by the draw-down technique onto Bonderite cold-rolled steel panels to form a 10-mil wet coating. The coatings were exposed to the ultraviolet light from a 300 watt-per-inch, medium-pressure mercury vapor lamp for 14 seconds. After ultraviolet light exposure the gel fraction content was determined and is reported as a percentage in Table 19. The gel fraction results indicate that insolublization took place under the conditions of ultraviolet light exposure and the coating-test properties indicate that a useful coating can be made from the compositions of this invention.
TABLE 19______________________________________ Examples 67 68 69 70______________________________________Ingredients, gramsExample 59 emulsion product 20.0 20.0 20.0 20.0Photoinitiator I -- 0.26 0.26 0.26Trimethylol propane -- -- 0.60 --triacrylatePentaerythritol triacrylate -- -- -- 0.60Surfactant 5 1 Drop 1 Drop 1 Drop 1 DropGel Fraction, % 40.0 56.1 65.2 65.0Cured Film PropertiesThickness, mils 2.0 1.8 1.8 1.9Gloss, 60° 89 73 80 81Pencil Scratch Hardness 3H 4H 3H 4HAcetone Double Rubs 100 100+ 100+ 100+______________________________________
PREPARATION H
Preparation of a copolymer with free carboxylic acid groups by solution polymerization
The following ingredients were charged to a dried three-neck round-bottom reaction flask equipped with a stirrer, nitrogen purge, and condenser: 302.4 grams of acetonitrile, 6.854 grams of methyl trimethyl silyl dimethyl ketene acetal, and 1.63 milliliters of 0.1M tri(dimethylamino)sulfur (trimethyl silyl) difluoride in acetonitrile (catalyst). A liquid monomer mixture composed of 174.38 grams of methyl methacrylate, 107.1 grams of 2-ethylhexyl methacrylate, and 48.26 grams of trimethyl silyl methacrylate was fed to the reactor over a 37-minute time period. Then an additional 0.7 milliliter of catalyst was added to the reactor. The temperature increased from 23° C. to 33° C. during this time period. After 17 hours, 44 grams of a 50% water-tetrahydrofuran solution was added to the polymer solution, and the mixture was heated for 2 hours at 60° C. The polymer was precipitated by slowly pouring into water, vacuum dried (2 mm Hg) overnight at 80° C. When the polymer is precipitated in water, the trimethyl silyl methacrylate is hydrolyzed and a carboxylic acid group is formed. The yield was 298.1 grams of polymer with a Mn=9640 and Mw/Mn=1.08. The acid number of the polymer was 61.6.
EXAMPLE 71
Solution preparation of a copolymer with pendant ethylenically unsaturated groups
Forty-four grams of the Preparation H copolymer containing free carboxylic acid groups, 160 grams of tetrahydrofuran, and 4.4 grams of triethylamine were added to a three-neck, round-bottom reaction flask equipped with a stirrer, nitrogen purge, and condenser. The reaction mass was heated to 60° C. Then 9.3 grams of Preparation A cyclohexyl carbodiimide ethyl methacrylate dissolved in 10 grams of tetrahydrofuran were fed to the reactor over a 10-minute time period. The reaction temperature was increased to 80° C. and held at this temperature for 44.5 hours. The resulting polymer was then precipitated into water, air dried for 2 days, and vacuum dried at 60° C. for 1.5 hours. There was a yield of 49 grams of the desired product which infrared analysis indicated analysis confirmed as containing ethylenic unsaturation from free methacrylate double bonds.
EXAMPLES 72-74
Evaluation of solution copolymer
The ingredients listed in Table 20 were well mixed and 4-mil wet films were drawn down on Bonderite cold-rolled steel panels. The coated panels were cured for 30 minutes at the indicted temperature in a forced-air oven. After the films were cured, approximately 50 milligram samples of each were removed and extracted for 18 hours in a Soxhlet extractor using tetrahydrofuran as the extractant. The extracted films were dried at 110° C. for 1 hour and then gel fraction, as a percentage was determined. The results given in Table 20 indicate that the films had a high gel content.
TABLE 20______________________________________ ExamplesIngredients, grams 72 73 74______________________________________Example 71 solution copolymer 5.0 5.0 5.0t-Butyl peroxybenzoate 0.25 0.25 0.25Methyl Propasol ® acetate 4 -- --Divinyl adipate -- 4.5 4.0Pentaerythritol tetracrylate -- -- 3.0Cure Temperature Gel Fraction, %120° C. 58.6 95.7 95.4140° C. 69.1 96.3 97.8160° C. 78.6 97.4 99.7______________________________________
EXAMPLE 75
An radiation curable formulation was prepared by dissolving 5 grams of Example 71 solution copolymer and 0.1 gram of Photoinitiator 1 in 4.5 grams of divinyl adipate. A 4-mil wet film was drawn down onto a Bonderite cold-rolled steel panel and exposed to a 300 watt-per-inch medium-pressure mercury vapor lamp for 56 seconds. After exposure a 50 milligram sample was removed and gel fraction was determined as in Examples 72-74 to be 54.2% indicating significant reaction took place.
EXAMPLE 76
In the same manner as described in Example 75 except that 1.0 gram of divinyl adipate and 5 grams of pentaerythritol tetracrylate were used as solvent, another ultraviolet light curable formulation was prepared and coated. Exposure was for 11 seconds under the same radiation source. The gel fraction was found to be 93.8% indicating a very high degree of reaction.
Although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby; but, rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof.
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This invention relates to reactive polymers, e.g., aqueous emulsion polymers, having pendant flexible or dangling side chains prepared from ethylenically unsaturated carbodiimides, e.g., carbodiimide (meth)acrylates. The reactive polymers contain ethylenic unsaturation near the surface or in the surface area of the particles that form the polymers, the ethylenic unsaturation being connected to the polymer through the pendant flexible or dangling side chains. This invention also relates to the process for preparing the reactive polymers, to crosslinkable formulations based on the reactive polymers, and to thermoplastic and crosslinked films prepared from the reactive polymers. The reactive polymers are useful as decorative and functional coatings, inks, adhesives, textile coatings and sealants.
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BACKGROUND
[0001] Infections are a significant problem in many fields where sanitary conditions are important, such as in healthcare. Problematic infections may arise from bacterial, fungal, amoebic, protozoan and/or viral organisms. Challenges are encountered both in preventing infection, and in reducing or eliminating the infection once it is established. Infected environments may include surfaces of objects, fluids and fluid conduits and/or humans or animals.
[0002] Alcohol solutions and isopropyl alcohol wipes are commonly used to disinfect surfaces and have been shown to have antibacterial activity. The most effective inhibitory anti-microbial effect is seen with 70% isopropanol solutions. Alcohol solutions at this concentration are quite expensive and rapidly evaporate, which substantially diminishes their efficacy and increases their cost. Moreover, although isopropanol solutions may be used for surfaces, including human skin, and in a variety of medical applications, alcohol solutions of this concentration cannot be administered to humans, for medical purposes, other than topically.
[0003] In the healthcare field, infections of various types and causes are common and often result in longer hospital stays, producing higher hospital costs. Even worse, over 90,000 patient deaths annually are attributed to nosocomial infections—that is, infections acquired at a hospital or in another healthcare environment. Surveillance for nosocomial infection has become an integral part of hospital practice. Studies conducted more than 20 years ago by the Centers for Disease Control and Prevention (CDC) documented the efficacy of these surveillance activities in reducing nosocomial infection occurrence. Despite the attention paid to problems of nosocomial infection, however, infection rates have not been dramatically reduced, and nosocomial infections remain a substantial risk and a substantial health concern.
[0004] One problematic source of infections in the medical and veterinary fields is found in catheters, and particularly in in-dwelling catheters. Catheters have become essential in the management of critical care patients, yet the inside of a catheter is often the major source of infection. Catheters are used for delivery of fluids, blood products, drugs, nutrients, hemodialysis, hemofiltration, peritoneal dialysis, retrieval of blood samples, monitoring of patient conditions, etc. Transcutaneous catheters often become infected through skin penetration of the catheter. It has been found that seventy percent (70%) of all nosocomial bloodstream infections occur in patients with central venous catheters. Daouicher et al. 340, 1-8, NEW ENGLAND JOURNAL OF MEDICINE (1999).
[0005] In particular, during some procedures, a catheter must be implanted in, and remain implanted in, a patient for a relatively long period of time, e.g. over thirty days. Intravenous (IV) therapy catheters and urinary catheters typically remain implanted for a substantial period of time. As a result of trauma to the areas of insertion, and pain to the patients, such catheters can't be removed and implanted frequently. Catheter-borne bacteria are implicated as a primary source of urinary tract infections. Patients who receive a peripherally inserted central catheter during pregnancy have also been found to be at significant risk for infectious complications. “Complications Associated With Peripherally Inserted Central Catheter Use During Pregnancy” AM. J. OBSTET. GYCOL. 188(5):1223-5 May 2003. In addition, central venous catheter infection, resulting in catheter related sepsis, has been cited as the most frequent complication during home parenteral nutrition. CLINICAL NUTRITION, 21(1):33-38, 2002. Because of the risk of infections, catheterization may be limited to incidences when the procedure is absolutely necessary. This seriously compromises patient health.
[0006] After most prescribed access medical procedures involving a catheter, the catheter is flushed with saline and then filled with a liquid, such as saline or a heparin solution, to prevent blood from clotting inside of the catheter, to inhibit the patient's blood from backing up into the catheter, and to prevent gases from entering the catheter. The liquid that is used to flush the catheter is referred to as a “lock-flush,” and the liquid used to fill the catheter following flushing or during periods of non-use is referred to as a “lock” solution.
[0007] Traditionally, catheters have been locked with normal saline or heparin solutions. Heparin and saline are sometimes used in combination. Normal saline is generally used to lock short term peripheral intravenous catheters, but saline has no anticoagulant or antimicrobial activity. Heparin solutions are generally used to lock vascular catheters. Heparin has anticoagulant activity but it does not function as an antimicrobial and does not prevent or ameliorate infections. There are also strong indications that heparin in lock solutions may contribute to heparin-induced thrombocytopenia, a serious bleeding complication that occurs in a subset of patients receiving heparin injections.
[0008] Catheter locking solutions comprising taurolidine, citric acid and sodium citrate have been proposed. A recent publication (Kidney International, September 2002) describes the use of a 70% alcohol solution as a lock solution for a subcutaneous catheter port. The use of alcohol as a lock solution is questionable, since it is not an anticoagulant, and since there would be risks associated with this solution entering the bloodstream. There is also no evidence that the inventors are aware of that indicates that a 70% alcohol solution has any biofilm eradication activity.
[0009] An emerging trend and recommendation from the Center for Infectious Disease (CID) is to treat existing catheter infections systemically with either a specific or a broad range antibiotic. Use of an antibiotic in a lock solution to prevent infection is not recommended. The use of antibiotics to treat existing catheter infections has certain risks, including: (1) the risk of antibiotic-resistant strains developing; (2) the inability of the antibiotic to kill sessile, or deep-layer biofilm bacteria, which may require the use of antibiotics at toxic concentrations; and (3) the high cost of prolonged antibiotic therapy. Catheters coated with a disinfectant or antibiotic material are available. These coated catheters may only provide limited protection for a relatively short period of time.
[0010] In general, free-floating organisms may be vulnerable to antibiotics. However, bacteria and fungi may become impervious to antibiotics by attaching to surfaces and producing a slimy protective substance, often referred to as extra-cellular polymeric substance (EPS), polysaccharide covering or glycocalyx. As the microbes proliferate, more than 50 genetic up or down regulations may occur, resulting in the formation of a more antibiotic resistant microbial biofilm. One article attributes two-thirds of the bacterial infections that physicians encounter to biofilms. SCIENCE NEWS, 1-5 Jul. 14, 2001.
[0011] Biofilm formation is a genetically controlled process in the life cycle of bacteria that produces numerous changes in the cellular physiology of the organism, often including increased antibiotic resistance (of up to 100 to 1000 times), as compared to growth under planktonic (free floating) conditions. As the organisms grow, problems with overcrowding and diminishing nutrition trigger shedding of the organisms to seek new locations and resources. The newly shed organisms quickly revert back to their original free-floating phase and are once again vulnerable to antibiotics. However, the free-floating organism may enter the bloodstream of the patient, creating bloodstream infections, which produce clinical signs, e.g. fever, and more serious infection-related symptoms. Sessile rafts of biofilm may slough off and may attach to tissue surfaces, such heart valves, causing proliferation of biofilm and serious problems, such as endocarditis.
[0012] To further complicate matters, conventional sensitivity tests measure only the antibiotic sensitivity of the free-floating organisms, rather than organisms in a biofilm state. As a result, a dose of antibiotics is administered to the patient, such as through a catheter, in amounts that rarely have the desired effect on the biofilm phase organisms that may reside in the catheter. The biofilm organisms may continue to shed more planktonic organisms or may go dormant and proliferate later as an apparent recurrent infection.
[0013] In order to eradicate biofilm organisms through the use of antibiotics, a laboratory must determine the concentration of antibiotic required to kill the specific genetic biofilm phase of the organism. Highly specialized equipment is required to provide the minimum biofilm eradication concentration. Moreover, the current diagnostic protocols are time consuming, and results are often not available for many days, e.g. five (5) days. This time period clearly doesn't allow for prompt treatment of infections. The delay and the well-justified fear of infection may result in the overuse of broad-spectrum antibiotics and continued unnecessary catheter removal and replacement procedures. Overuse of broad-spectrum antibiotics can result in the development of antibiotic resistant bacterial strains, which cannot be effectively treated. Unnecessary catheter removal and replacement is painful, costly and may result in trauma and damage to the tissue at the catheter insertion site.
[0014] The antibiotic resistance of biofilms, coupled with complications of antibiotic use, such as the risk of antibiotic resistant strains developing, has made antibiotic treatment an unattractive option. As a result, antibiotic use is limited to symptomatic infections and prophylactic antibiotics are not typically applied to prevent contamination. Because the biofilm can act as a selective phenotypic resistance barrier to most antibiotics, the catheter must often be removed in order to eradicate a catheter related infection. Removal and replacement of the catheter is time consuming, stressful to the patient, and complicates the medical procedure. Therefore, there are attempts to provide convenient and effective methods for killing organisms, and especially those dwelling inside of catheters, without the necessity of removing the catheter from the body.
[0015] In addition to bacterial and fungal infections, amoebic infections can be very serious and painful, as well as potentially life threatening. Several species of Acanthamoeba, for example, have been found to infect humans. Acanthamoeba are found worldwide in soil and dust, and in fresh water sources as well as in brackish water and sea water. They are frequently found in heating, venting and air conditioner units, humidifiers, dialysis units, and in contact lens paraphernalia. Acanthamoeba infections, in addition to microbial and fungal infections, may also be common in connection with other medical and dental devices, including toothbrushes, dentures and other dental appliances, and the like. Acanthamoeba infections often result from improper storage, handling and disinfection of contact lenses and other medical devices that come into contact with the human body, where they may enter the skin through a cut, wound, the nostrils, the eye, and the like.
[0016] There is a need for improved methods and substances to prevent and destroy infections in catheters. Such disinfectant solutions should have a broad range of antimicrobial properties. In particular, the solutions should be capable of penetrating biofilms to eradicate the organisms comprising the biofilms. The methods and solutions should be safe enough to be use as a preventive measure as well as in the treatment of existing infections.
[0017] Poly(hexamethylenebiguanide) (PHMB) is a broad spectrum, fast acting disinfectant. It is used as a preservative for make-up removers, moisturizing toners, facial cleansers, wet wipes and offers antibacterial and deodorant properties. It is available as Poly(hexamethylenebiguanide) hydrochloride (commonly known as polihexanide) in a solution form at a concentration of 20%. It is sold under the name of Cosmocil CQ via Avecia/Arch Chemicals.
[0018] Ethylene diamine tetraacetic acid (EDTA) has been used for systemic detoxification treatment and as an anticoagulant in blood samples for some time. Thus its use for medical treatment and applications is established. The use of disodium EDTA and calcium disodium EDTA in combination with other compounds to enhance anti-microbial properties of these other compounds has been studied and practiced. It has been discovered that many stand-alone salts of Ethylenediamine-tetraaceticacid (EDTA) are effective anti-microbial agents and that specific salts are more effective than others. In particular, it has been discovered that certain salts of EDTA exhibit anti-microbial (both antifungal and antibacterial) properties superior to those of the disodium salt in common use. In particular, dipotassium and ammonium EDTA are superior to disodium EDTA, and tetrasodium EDTA (TEDTA) has been found to be preferred to disodium, ammonium, and dipotassium.
OBJECTS AND SUMMARY
[0019] In the following discussion, the terms “microbe” or “microbial” will be used to refer to microscopic organisms or matter, including fungal and bacterial organisms, and possibly including viral organisms, capable of infecting humans. The term “anti-microbial” will thus be used herein to refer to a material or agent that kills or otherwise inhibits the growth of fungal and/or bacterial and possibly viral organisms.
[0020] The term “disinfect” will be used to refer to the reduction, inhibition, or elimination of infectious microbes from a defined system. The term “disinfectant” will be used herein to refer to a one or more anti-microbial substances used either alone or in combination with other materials such as carriers, solvents, or the like.
[0021] The term “bactericidal activity” is used to refer to an activity that at least essentially kills an entire population of bacteria, instead of simply just reducing or inhibiting their growth. The term “fungicidal activity” is used to refer to an activity that at least essentially kills an entire population of yeast, instead of simply just reducing or inhibiting their growth. Contamination of conduits, e.g., catheters, poses serious and substantial health risks and bactericidal disinfection is a significant priority.
[0022] The term “infected system” will be used herein to refer to a defined or discrete system or environment in which one or more infectious microbes are or are likely to be present. Examples of infected systems include a physical space such as a bathroom facility or operating room, a physical object such as food or surgical tool, a biological system such as the human body, or a combination of a physical object and a biological system such as a catheter or the like arranged at least partly within a human body. Tubes and other conduits for the delivery of fluids, in industrial and healthcare settings, may also define an infected system.
[0023] A solution that consists essentially of PHMB and EDTA salt(s) in a solvent, such as water or saline, is substantially free from other active substances having antimicrobial and/or anti-fungal activity.
[0024] The present disclosure involves disinfectant solutions comprising, or consisting essentially of, or consisting of, PHMB and EDTA salt(s) at a prescribed concentration and/or pH. The inventors have discovered, unexpectedly, that certain PHMB and EDTA salt(s) formulations provide enhanced disinfectant activities. PHMB and EDTA salt(s) formulations act as enhanced, fast acting catheter lock/flush solutions. PHMB and EDTA salt(s) formulations of the present disclosure are also highly effective in killing pathogenic biofilm organisms, and are expected to be effective in reducing existing biofilms, in eliminating existing biofilms as well as preventing biofilm formation. PHMB and EDTA salt(s) formulations function as broad-spectrum anti-microbial agents, as well as fungicidal agents against many strains of pathogenic yeast. PHMB and EDTA salt(s) formulations are expected to exhibit anti-protozoan activity and also exhibit anti-amoebic activity.
[0025] The PHMB and EDTA salt(s) formulations of the present disclosure are safe for human administration and are biocompatible and non-corrosive. The disinfectant solutions of the present disclosure have applications at least as lock and lock flush solutions for various types of catheters. The efficacy of the PHMB and EDTA salt(s) formulations of the present disclosure is superior to many disinfectant compositions conventionally used as catheter lock/flush solutions. The disclosed PHMB and EDTA salt(s) formulations do not contribute to antibiotic resistance, which provides yet another important benefit.
[0026] The PHMB and EDTA salt(s) formulations of the present disclosure are also have improved anticoagulant properties and are thus especially beneficial as catheter lock-flush solutions and other related uses.
[0027] In one embodiment, disinfectant compositions of the present disclosure have some of the following properties: anticoagulant properties; inhibitory and/or bactericidal activity against a broad spectrum of bacteria in a planktonic form; inhibitory and/or fungicidal activity against a spectrum of fungal pathogens; inhibitory and/or bactericidal activity against a broad spectrum of bacteria in a sessile form; inhibitory activity against protozoan infections; inhibitory activity against Acanthamoeba infections; safe and biocompatible, at least in modest volumes, in contact with a patient; and safe and biocompatible, at least in modest volumes, in a patient's bloodstream.
[0028] Methods for inhibiting the growth and proliferation of microbial populations and/or fungal pathogens are provided that comprise contacting an infected or suspected infected object, or surface, e.g., catheter, with a disinfectant composition of the present disclosure. Methods for inhibiting the growth and proliferation of protozoan populations are also provided, comprising contacting an infected or suspected infected object, or surface, e.g., catheter, with a disinfectant composition of the present disclosure.
[0029] Methods for inhibiting the growth and proliferation of amoebic populations, and for preventing amoebic infection, particularly Acanthamoeba infections, are provided, comprising contacting an object, or a surface, e.g., catheter, with a disinfectant composition of the present disclosure. Methods for substantially eradicating microbial populations are also provided and comprise contacting an infected or suspected infected object, or surface, e.g., catheter, with a disinfectant composition of the present disclosure. Methods for substantially eradicating an Acanthamoeba population are provided and comprise contacting an infected or suspected infected object, or surface, e.g., catheter, with a disinfectant composition of the present disclosure. Depending on the disinfectant composition used in the various methods, various compositions and contact time periods may be required to inhibit the formation and proliferation of various populations, and/or to substantially eradicate various populations. Suitable contact time periods for various compositions may be determined by routine experimentation.
[0030] Importantly, in most embodiments, disinfectant compositions and methods of the present disclosure do not employ traditional antibiotic agents and thus do not contribute to the development of antibiotic resistant organisms.
[0031] In one embodiment, disinfectant compositions consisting of, consisting essentially of, or comprising PHMB and EDTA salt(s) at a greater than physiological pH are provided as disinfectant compositions of the present disclosure. Such disinfectant compositions have application as lock solutions and lock flush solutions for various types of in-dwelling access catheters, including vascular catheters used for delivery of fluids, blood products, drugs, nutrition, withdrawal of fluids or blood, dialysis, monitoring of patient conditions, and the like. Disinfectant solutions of the present disclosure may also be used as lock and lock flush solutions for urinary catheters, nasal tubes, throat tubes, and the like. The general solution parameters described below are suitable for these purposes. In one embodiment, a disinfectant solution consisting of, consisting essentially of, or comprising PHMB and EDTA salt(s) at a greater than physiological pH is provided to maintain the patency of in-dwelling intravascular access devices. Methods for disinfectant catheters and other medical tubes, such as nasal tubes, throat tubes, and the like, are also provided and involve contacting the catheter or other medical tube with a disinfectant composition of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0032] FIG. 1 shows the results of experiments of a PHMB MIC test with P. aeruginosa. The data suggests that the MIC value for PHMB is <5 PPM.
[0033] FIG. 2 shows the results of experiments of a PHMB MIC test with S. aureus. The data suggests that the MIC value for PHMB is <1.25 PPM.
[0034] FIG. 3 shows the results of experiments of a PHMB MIC test with C. Albicans. The data suggests that the MIC value for PHMB is <1.25 PPM.
[0035] FIG. 4 shows the results of experiments of a PHMB MBC test with C. Albicans. The data suggests that the MBC value for PHMB is <1.25 PPM.
[0036] FIG. 5 shows the results of experiments of a EDTA(Na 4 ) MIC test with P. aeruginosa. The data suggests that the MIC value for EDTA(Na 4 ) is <0.25 wt %.
[0037] FIG. 6 shows the results of experiments of a EDTA(Na 4 ) MIC test with S. aureus. The data suggests that the MIC value for EDTA(Na 4 ) is <0.03125 wt %.
[0038] FIG. 7 shows the results of experiments of a EDTA(Na 4 ) MIC test with C. Albicans. The data suggests that the MIC value for EDTA(Na 4 ) is <0.03125 wt %.
[0039] FIG. 8 shows the results of experiments of a EDTA(Na 4 ) MBC test with C. Albicans. The data suggests that the MBC value for EDTA(Na 4 ) is <0.0625 wt %.
[0040] FIG. 9 shows the results of experiments of a Checkerboard Titration with S. aureus. The data suggests that the FIC index=0.8 for EDTA(Na 4 )+PHMB Combination.
[0041] FIG. 10 shows the results of experiments of a Checkerboard Titration with P. aeruginosa. The data suggests that the FIC index=0.5 for EDTA(Na 4 )+PHMB Combination.
[0042] FIG. 11 shows the results of experiments of a Checkerboard Titration with C albicans. The data suggests that the FIC index=0.6 for EDTA(Na 4 )+PHMB Combination.
[0043] FIG. 12 shows the results of experiments of a Rate Kill Assay for S. aureus. The data clearly suggest the synergistic action against S. Aureus by EDTA(Na 4 )+PHMB combination.
[0044] FIG. 13 shows the results of experiments of a Rate Kill Assay for P. aeruginosa. The data clearly suggest the synergistic action against P. aeruginosa by EDTA(Na 4 )+PHMB combination.
[0045] FIG. 14 shows the results of experiments of a Rate Kill Assay for C. albicans. The data does not suggest the synergistic action against C. albicans by EDTA(Na 4 )+PHMB combination. However, the data suggests the combination is very effective against C. albicans with PHMB being the dominant component.
[0046] FIG. 15 shows the results of experiments of a PHMB MIC and MBC test with S. aureus at a pH of 7. The data suggests that the MIC value for PHMB at a pH of 7 is <5 PPM. The data suggests that the MBC value for PHMB at a pH of 7 is <5 PPM.
[0047] FIG. 16 shows the results of experiments of a PHMB MIC and MBC test with P. aeruginosa at a pH of 7. The data suggests that the MIC value for PHMB at a pH of 7 is <5 PPM. The data suggests that the MBC value for PHMB at a pH of 7 is <5 PPM.
[0048] FIG. 17 shows the results of experiments of a PHMB MIC and MBC test with C. albicans at a pH of 7. The data suggests that the MIC value for PHMB at a pH of 7 is <10 PPM. The data suggests that the MBC value for PHMB at a pH of 7 is <10 PPM.
[0049] FIG. 18 shows the results of experiments of a EDTA MIC and MBC test with S. aureus at a pH of 7. The data suggests that the MIC value for EDTA at a pH of 7 is <0.03 wt %. The data suggests that the MBC value for EDTA at a pH of 7 is <0.13 wt %.
[0050] FIG. 19 shows the results of experiments of a EDTA MIC and MBC test with P. aeruginosa at a pH of 7. The data suggests that the MIC value for EDTA at a pH of 7 is <0.25 wt %. The data suggests that the MBC value for EDTA at a pH of 7 is <4.00 wt %.
[0051] FIG. 20 shows the results of experiments of a EDTA MIC test with C. albicans at a pH of 7. The data suggests that the MIC value for EDTA at a pH of 7 is >4.0 wt %. The MBC value for EDTA at a pH of 7 could not be determined.
[0052] FIG. 21 shows the results of experiments of a Checkerboard Titration with S. aureus at a pH of 7. The data suggests that the FIC index=0.6 for PHMB-EDTA Combination at a pH of 7.
[0053] FIG. 22 shows the results of experiments of a Checkerboard Titration with P. aeruginosa at a pH of 7. The data suggests that the FIC index=0.5 for PHMB-EDTA Combination at a pH of 7.
[0054] FIG. 23 shows the results of experiments of a Checkerboard Titration with C. albicans at a pH of 7. The data suggests that there is no synergy against C. ablicans for PHMB-EDTA Combination at a pH of 7.
[0055] FIG. 24 shows the results of experiments (raw data) of a Prothrombin Time (PT) Assay.
[0056] FIG. 25 shows the results of experiments (processed data) of a Prothrombin Time (PT) Assay.
[0057] FIG. 26 shows the graph of the International Normalized Ratio (INR) for EDTA(Na 4 ) from a Prothrombin Time (PT) Assay.
[0058] FIG. 27 shows the graph of the International Normalized Ratio (INR) for PHMB from a Prothrombin Time (PT) Assay.
[0059] FIG. 28 shows the graph of the International Normalized Ratio (INR) for combined EDTA(Na 4 ) and PHMB formulations from a Prothrombin Time (PT) Assay.
DETAILED DESCRIPTION
[0060] Disinfectant compositions of the present disclosure may comprise concentrations of PHMB and EDTA salt(s) at a pH higher than physiological. PHMB and EDTA salt(s) may be used in compositions with water as the solvent.
[0061] Some properties of PHMB are:
[0062] Physical Properties
Color—Colorless to slightly pale yellow Solubility—Miscible with water, ethanol, glycerine and propylene glycol Specific Gravity at 25° C.-1.04 pH—5.0-5.5 Shelf Life—greater than two year storage stability Stability—Effective and stable over a broad pH range (4-10) active agent heat stable to >140° C. UV stable odorless, non-foaming Chemically stable and non-volatile
[0073] Chemical Properties
Zero Volatile Organic Compound Compatible with a wide range of cosmetic raw materials Compatible with cationic, amphoteric and non-ionic surfactants Incompatible with strongly anionic systems
[0078] Antimicrobial Properties
Unique biguanide chemistry Novel non-specific mode of action No known evidence of development of organism resistance Contains no formaldehyde and is not a formaldehyde donor Broad spectrum of activity high activity vs. tough Gram (negative) organisms, e.g., Pseudomonas Extensively studied mammalian toxicity Low acute toxicity via dermal and oral routes Low skin and eye irritancy potential at in-use concentration Slow toxicity following long term exposure Not teratogenic and shows no reproductive effects when studied over two generations Non-genotoxic in a range of studies Not considered carcinogenic in humans.
[0091] Compositions comprising PHMB have a well established safety profile in connection with medical usage and administration to humans. Acute Oral LD 50 of 1617 mg/kg (see table below for further info).
[0000]
Guideline
Toxicity
No.
Study Type
MRID #(s)
Results
Category
Acute Toxicity
870.1100
Acute Oral
00030330
LD50 = 2747 mg/kg
III
44940701
LD50 = 1831 mg/kg (M) LD50 =
1617 mg/kg (F)
45916505
LD50 = 1049 mg/kg (F)
870.1200
Acute Dermal
00065124
LD50 > 2.0 ml/kg
III
44940702
LD50 > 2000 mg/kg
45916506
LD50 > 5000 mg/kg
IV
870.1300
Acute Inhalation
44970403
LC50 = 1.76 mg/L
III
870.2400
Primary Eye Irritation
00046789
Moderate irritant
II
00065120
44963902
870.2500
Primary Skin Irritation
00046789
Moderate irritant
II
00065120
44949704
Slight irritant
IV
45916509
870.2600
Dermal Sensitization
42674201
Moderate sensitizer
NA
44940705
Mild sensitizer
Notes:
LC = Lethal Concentration;
LD = Lethal Dose;
NA = Not Applicable
[0000]
Special FQPA SF*
and Level of
Exposure
Dose Used in Risk
Concern for Risk
Scenario
Assessment, UF
Assessment
Study and Toxicological Effects
Acute Dietary
NOAEL = 20 mg/kg/day
FQPA SF = 1
Rabbit Developmental Study
(Females 13-50
UF = 100
aPAD = acute RfD
(MRID 42865901)
years of age)
Acute RfD = 0.2 mg/kg/day
FQPA SF =
LOAEL = 40 mg/kg/day based on reduced
0.2 mg/kg/day
number of litters and skeletal
abnormalities.
Acute Dietary
No Appropriate single dose effects can be selected for general population
(General population
including infants and
children)
Chronic Dietary (All
NOAEL = 20 mg/kg/day
FQPA SF = 1 cPAD =
Rabbit Developmental Study (MRID
populations)
UF = 100
chronic RfD FQPA
42865901) LOAEL = 40 mg/kg/day
Chronic RfD = 0.2 mg/kg/day
SF = 0.2 mg/kg/day
Based on the increased mortality, reduced
food consumption, and clinical toxicity;
Mouse Developmental Study (Report No.
CTL/P/335, 1977 (cited in Report No.
003810, 1978. Section C-9))
LOAEL = 40 mg/kg/day;
Based on reduced body weight gain; and
Rat Developmental Study (Report No.
CTL/P/1262, 1976 (cited in Report No.
003810, 1978. Section C-11))
LOAEL = 50 mg/kg/day
Based on reduced food consumption.
Cancer (Oral,
The HED Cancer Assessment Review Committee (CARC) classified PHMB as
dermal, Inhalation)
“Suggestive Evidence of Carcinogenicity, but not sufficient to Assess Human Carcinogenic
Potential” by the oral and dermal routes. Quantification of human cancer risk is not
required.
Notes:
UF = uncertainty factor,
FQPA SF = Food Quality Protection Act safety factor,
NOAEL = no observed adverse effect level,
LOAEL = lowest observed adverse effect level,
PAD = population adjusted dose (a = acute, c = chronic)
RfD = reference dose
Reference —Re-registration Eligibility Decision for PHMB, September 2005.
[0092] PHMB is also present, in combination with other components, in many solutions used in medical and human health applications, and has been established as safe for human use, both in vitro and in vivo. PHMB is readily available at a reasonable cost, and is stable over time in solution.
[0093] Soluble salts of EDTA are used in compositions of the present disclosure. Sodium salts of EDTA are commonly available and generally used, including di-sodium, tri-sodium and tetra-sodium salts, although other EDTA salts, including ammonium, di-ammonium, potassium, di-potassium, cupric di-sodium, magnesium di-sodium, ferric sodium, and combinations thereof, may be used, provided they have the antibacterial and/or fungicidal and/or anti-protozoan and/or anti-amoebic properties desired, and provided that they are sufficiently soluble in the solvent desired. Various combinations of EDTA salts may be used and may be preferred for particular applications.
[0094] The British Pharmacopoeia (BP) specifies that a 5% solution of di-sodium EDTA has a pH of 4.0 to 5.5. The BP also specifies a pH range of 7.0 to 8.0 for solutions of tri-sodium EDTA. At physiological pH, the sodium salts of EDTA exist as a combination of di-sodium and tri-sodium EDTA, with the tri-sodium salt of EDTA being predominant. In the U.S., pharmaceutical “di-sodium” EDTA prepared for injection has generally been titrated with sodium hydroxide to a pH of 6.5 to 7.5. At this pH, the EDTA solution actually comprises primarily tri-sodium EDTA, with a lesser proportion of the di-sodium salt. Other compositions comprising sodium salts of EDTA that are used in medical or healthcare applications are generally adjusted to a pH that is substantially physiological.
[0095] Compositions comprising EDTA have a well established safety profile in connection with medical usage and administration to humans. Doses of up to 3000 mg EDTA disodium are infused over 3 hours, on a daily basis, for the treatment of hypercalcemia in humans. This dose is well tolerated. EDTA salts are also present, in combination with other components, in many solutions used in medical and human health applications, and have been established as safe for human use, both in vitro and in vivo. EDTA salts are readily available at a reasonable cost, and are stable over time in solution.
[0096] The combination of PHMB and EDTA salt(s) has an anti-coagulant effect. The anti-coagulant effect is further detailed in FIG. 28 .
[0097] Embodiments of the disclosed composition may comprise at least 0.1 PPM PHMB and up to 400 PPM PHMB. Embodiments comprising at least 5 PPM PHMB and less than 200 PPM PHMB are preferred for many applications, and compositions comprising about 10-50 PPM PHMB are especially preferred.
[0098] Embodiments of the disclosed composition may comprise at least 0.0125% EDTA salt(s), by weight per volume solution (w/v) and up to 12.0% (w/v) EDTA salt(s). Embodiments comprising at least 0.25% (w/v) EDTA salt(s) and less than 8% (w/v) EDTA salt(s) are preferred for many applications, and compositions comprising about 0.5-4 (w/v) EDTA salt(s) are especially preferred.
[0099] Embodiments of the disclosed composition may comprise between 0 and 25% (v/v) ethanol and water. Other embodiments of the disclosed composition may comprise between 0 and 20% (v/v) ethanol and water, between 0 and 15% (v/v) ethanol and water, or between 0 and 10% (v/v) ethanol and water.
[0100] The desired PHMB and EDTA salt(s) concentrations for various applications may depend on the type of infection being treated and, to some degree, on the solvent used for disinfectant compositions. When aqueous solvents comprising ethanol are used, for example, the concentrations of PHMB and EDTA salt(s) required to provide the desired level of activity may be reduced compared to the PHMB and EDTA salt(s) concentrations used in compositions having water as the solvent. “Effective” concentrations of PHMB and EDTA salt(s) in disinfectant compositions of the present disclosure for inhibitory, bactericidal, fungicidal, biofilm eradication and other purposes, may be determined by routine experimentation.
[0101] In certain embodiments, disinfectant compositions of the present disclosure comprise, or consist essentially of, or consist of, PHMB and EDTA salt(s) in solution at a pH higher than physiological, preferably at a pH of > or >8.0, or at a pH > or >8.5, or at a pH> or >9, or at a pH> or >9.5, or at a pH>or >10.0, or at a pH> or >10.5. Compositions comprising PHMB and EDTA salt(s) that are used in medical or healthcare applications may be adjusted to a pH that is substantially physiological. In one embodiment, disinfectant compositions of the present disclosure comprise, or consist essentially of, or consist of, PHMB and a sodium EDTA salt (or combination of sodium salts) in solution at a pH in the range between 8.5 and 12.5 and, in another embodiment, at a pH of between 9.5 and 11.5 and, in yet another embodiment, at a pH of between 10.5 and 11.5. When used herein, the term “EDTA salt” may refer to a single salt, such as a di-sodium or tri-sodium or tetra-sodium salt, or another EDTA salt form, or it may refer to a combination of such salts. The composition of EDTA salt(s) depends both on the EDTA salts used to formulate the composition, and on the pH of the composition. For disinfectant compositions of the present disclosure comprising sodium EDTA salt(s), and at the desired pH ranges (specified above), the sodium EDTA salts are predominantly present in both the tri-sodium and tetra-sodium salt forms.
[0102] Disinfectant compositions comprising, or consisting essentially of, or consisting of PHMB and EDTA salt(s) have different “effective” pH ranges. “Effective” pH ranges for desired EDTA salt(s) in disinfectant compositions of the present disclosure for inhibitory, bactericidal, fungicidal, biofilm eradication and other purposes, may be determined by routine experimentation.
[0103] In some embodiments, disinfectant compositions of the present disclosure consist of PHMB and EDTA salt(s), as described above, and disinfectant solutions consist of PHMB and EDTA salt(s) dissolved in a solvent, generally an aqueous solvent such as water or saline. In other embodiments, disinfectant compositions of the present disclosure consist essentially of PHMB and EDTA salt(s), as described above, generally in an aqueous solvent such as water or saline.
[0104] In some embodiments, disinfectant compositions of the present disclosure comprise PHMB and EDTA salt(s) having specified concentrations, at specified pH ranges, and may contain materials, including active components, in addition to the PHMB and EDTA salt(s) described above. Other antimicrobial or biocidal components may be incorporated in disinfectant compositions of the present disclosure comprising PHMB and EDTA salt(s), although the use of traditional antibiotics and biocidal agents is generally discouraged as a result of the potential dire consequences of the development of antibiotic- and biocidal-resistant organisms. In some embodiments, disinfectant compositions of the present disclosure comprising PHMB and EDTA salt(s) having specified concentration(s), at specified pH ranges, are substantially free from other active substances having substantial antimicrobial and/or anti-fungal activity.
[0105] Other active and inactive components may also be incorporated in disinfectant compositions of the present disclosure comprising PHMB and EDTA salt(s), preferably provided that they don't deleteriously affect the activity and/or stability of the PHMB and EDTA salt(s). Proteolytic agents may be incorporated in disinfectant compositions for some applications. Disinfectant compositions formulated for topical application have various creams, emollients, skin care compositions such as aloe vera, and the like, for example. Disinfectant compositions of the present disclosure provided in a solution formulation may also comprise other active and inactive components, preferably provided they don't interfere, deleteriously, with the activity and/or stability of the PHMB and EDTA salt(s).
[0106] The compositions of the present disclosure may be used in a solution or a dry form. In solution, the PHMB and EDTA salt(s) are preferably dissolved in a solvent, which may comprise an aqueous solution, such as water or saline, or another biocompatible solution in which the PHMB and EDTA salt(s) are soluble. Other solvents, including alcohol solutions, may also be used. In one embodiment, PHMB and EDTA salt(s) compositions of the present disclosure may be formulated in a mixture of water and ethanol. Such solutions are expected to be highly efficacious and may be prepared by making a concentrated PHMB and EDTA salt(s) stock solution in water and then introducing the desired concentration of ethanol. Ethanol concentrations of from more than about 0.5% and less than about 10%, v/v, are expected to provide effective disinfectant compositions. In some embodiments, bio-compatible non-aqueous solvents may also be employed, provided the EDTA salt(s) can be solubilized and remain in solution during storage and use.
[0107] PHMB and EDTA salt(s) solutions of the present disclosure are preferably provided in a sterile and non-pyrogenic form and may be packaged in any convenient fashion. In some embodiments, disinfectant PHMB and EDTA salt(s) compositions of the present disclosure may be provided in connection with or as part of a medical device, such as in a pre-filled syringe or another medical device. The compositions may be prepared under sterile, aseptic conditions, or they may be sterilized following preparation and/or packaging using any of a variety of suitable sterilization techniques. Single use vials, syringes or containers of PHMB and EDTA salt(s) solutions may be provided. Multiple use vials, syringes or containers may also be provided. Systems of the present disclosure include such vials, syringes or containers containing the PHMB and EDTA salt(s) solutions of the present disclosure. Catheters contemplated for use include peripherally inserted catheters, central venous catheters, peritoneal catheters, hemodialysis catheters and urological catheters.
[0108] The compositions of the present disclosure may also be provided in a substantially “dry” form, such as a substantially dry coating on a surface of tubing, or a conduit, or a medical device such as a catheter or conduit, or a container, or the like. Dry forms of the disinfectant compositions of the present disclosure may include hydrophilic polymers such as PVP, which tend absorb water and provide lubricity, surfactants to enhance solubility and/or bulking and buffering agents to provide thermal as well as pH stability. Such substantially dry forms of PHMB and EDTA salt(s) compositions of the present disclosure may be provided in a powder or lyophilized form that may be reconstituted to form a solution with the addition of a solvent. Substantially dry forms of PHMB and EDTA salt(s) compositions may alternatively be provided as a coating, or may be incorporated in a gel or another type of carrier, or encapsulated or otherwise packaged and provided on a surface as a coating or in a container. Such substantially dry forms of PHMB and EDTA salt(s) compositions of the present disclosure are formulated such that in the presence of a solution, the substantially dry composition forms an PHMB and EDTA salt(s) solution having the composition and properties described above. In certain embodiments, different encapsulation or storage techniques may be employed such that effective time release of the PHMB and EDTA salt(s) is accomplished upon extended exposure to solutions. In this embodiment, the substantially dry PHMB and EDTA salt(s) solutions may provide disinfectant activity over an extended period of time and/or upon multiple exposures to solutions.
[0109] Formulation and production of disinfectant compositions of the present disclosure are generally straightforward. In one embodiment, desired disinfectant compositions of the present disclosure are formulated by dissolving PHMB and EDTA salt(s) in an aqueous solvent, such as purified water, to the desired concentration and adjusting the pH of the solution to the desired pH. In alternative embodiments, desired disinfectant compositions of the present disclosure are formulated by dissolving PHMB and EDTA salt(s) in a solvent in which the PHMB and EDTA salt(s) are soluble to provide a concentrated, solubilized solution, and additional solvents or components may then be added, or the solubilized composition may be formulated in a form other than a solution, such as a topical preparation. The disinfectant solution may then be sterilized using conventional means, such as filtration and/or ultrafiltration, and other means. The preferred osmolarity range for PHMB and EDTA salt(s) solutions is from 240-500 mOsm/Kg, more preferably from 300-420 mOsm/Kg. The solutions are preferably formulated using USP materials.
[0110] A PHMB and EDTA salt(s) solution can be used as a treatment for catheters defining an infected system. The PHMB and EDTA salt(s) solution may inhibit microbe colonization by treating the catheter with the solution at the prescribed concentration using a liquid lock prior to and in between infusions and/or by surface coating of catheter devices. A further application is the treatment of colonized or infected catheters by use of a liquid lock containing the PHMB and EDTA salt(s) solution in the preferred concentration and pH.
[0111] Typically, the PHMB and EDTA salt(s) solution, when used to treat catheters, are dissolved in water as a carrier, although other carriers may be used. Substances such as thrombolytics, sodium, alcohol, or reagents may also be added to the basic water/PHMB and EDTA salt(s) solution.
Minimum Inhibitory Concentration (MIC) Experiments
[0112] The minimum concentration of a composition required to inhibit growth is known as the minimum inhibitory concentration (MIC). In order to determine MIC and MBC (minimum bactericidal concentration) a National Committee on Clinical Laboratory Standards (NCCLS) micro-dilution procedure was followed. According to the procedure each formulation must be exposed to 6 log concentration (or the highest achievable concentration) of organism. In the current protocol 100 μL of MHB was mixed with 90 μL of formulation and 10 μL of log 8 concentration organism (or the highest achievable concentration). The concentration of the formulation was adjusted to obtain the required concentration in the final solution. The mixture was incubated at 37 degree C for 16-24 hrs. After 16-24 hours the absorbance value was read at 600 nm. The obtained data was corrected by subtracting the appropriate blanks. Finally, the wells having an absorbance >0.1 were marked + and <0.1 were marked −. The +symbol indicated growth while −symbol indicates no growth. The positive growth controls must have a corrective absorbance value of >0.5 and negative controls must have a corrected absorbance value of <0.1. In cases where the positive growth controls corrected absorbance is lower than 0.5, an alternate rule is utilized which is “absorbance <than 20% of positive growth control is marked as −growth, while absorbance >than 20% of positive growth control is marked as +growth”.
[0113] Staphylococcus aureus (Organism #25923), Pseudomonas aeruginosa (Organism #27853), and Candida Albicans (Organism #10231) was obtained from ATCC. PHMB was used (Avecia, Lot #1L15-038). EDTA, tetrasodium salt hydrate, was used (Alfa Aesar, Catalogue #A17385, Lot #J9570A). A 200 PPM PHMB solution in water was prepared. A 8 wt % EDTA(Na 4 ) solution in water was prepared. These solutions were then diluted as necessary to obtain the required concentrations. A minimum concentration of EDTA(Na 4 ) and PHMB that inhibited the growth of Staphylococcus aureus and P. aeruginosa was found. As per experiments conducted, EDTA(Na 4 ) has a MIC of <0.03% (w/v) for S. aureus, PHMB has a MIC of <1.25 PPM for S. aureus, EDTA(Na 4 ) has a MIC of <0.25% (w/v) for P. aeruginosa, PHMB has a MIC of <5 PPM for P. aeruginosa, EDTA(Na 4 ) has a MIC of <0.03125% (w/v) for C. albicans, PHMB has a MIC of <1.25 PPM for C. albicans, EDTA(Na 4 ) has a MBC of <0.0625% (w/v) for C. albicans, PHMB has a MBC of <1.25 PPM for C. albicans. See FIGS. 1-8 for MIC and MBC results.
Synergism Experiment
[0114] Two sets of experiments were conducted to show an unexpected synergism of the disinfectant activity of a composition that includes both EDTA(Na 4 ) and PHMB.
[0115] The first experiment conducted was a screening experiment using checkerboard titration to assess if the combinations fall within a range having an FIC index value of <1. The method used was a NCCLS micro-dilution procedure
[0116] The second experiment conducted was a “rate of kill” assay. A rate of kill assay can confirm whether combinations are synergistic or not. In this assay the formulations are first exposed to organisms for a desired time (the current formulations readings were taken at 0, 1, 2, 3 and 24 hrs). Then a sample of the organisms and formulation mixture is serially diluted and plated to assess the log recovery. The organisms are allowed to grow and are checked for growth/log recovery after 24 hrs. The log recovery values obtained for individual components were compared with the combinations. Any combinations having >2 log reduction when compared with the most active compound used in the combination at any time point tested were labeled as synergistic (Comparison of methods for assessing synergic antibiotic interactions, International journal of antimicrobial agents, 15 (2000) 125-129).
[0117] According to the first and second experiments described above, experiments were conducted to investigate the effect of PHMB on the antimicrobial activity of EDTA(Na 4 ). PHMB was used (Avecia, Lot #1L15-038). EDTA, tetrasodium salt hydrate, was used (Alfa Aesar, Catalogue #A17385, Lot #J9570A).
Checkerboard Titration Experiment— S. Aureus
[0118] The Checkerboard Titration method was used to assess the interactions between EDTA(Na 4 ) and PHMB. The Checkerboard Titration method is a frequently used technique where, for example, each agent (EDTA(Na 4 ) and PHMB) was tested at multiple dilutions lower than the MIC. During this experiment, EDTA(Na 4 ) and PHMB were tested in the combinations to assess if the combinations have an FIC index of <1. The following concentrations were tested:
[0000]
Concentration
Concentration PHMB
Combination
EDTA(Na 4 ) (wt %)
(PPM)
0.5 MIC + 0.5 MIC
0.0156
0.625
0.4 MIC + 0.4 MIC
0.0125
0.5
0.35 MIC + 0.35 MIC
0.01093
0.4375
0.3 MIC + 0.3 MIC
0.0093
0.375
0.25 MIC + 0.25 MIC
0.00781
0.3125
0.125 MIC + 0.125 MIC
0.0039
0.15625
[0119] Fraction Inhibitory Concentration (FIC) is defined as the MIC of the compound in combination divided by the MIC of the compound alone. If the FIC index is <0.5, the combination is interpreted to be synergistic; <1 but >0.5—as partially synergistic; =1 as additive; >1 but <4 as indifferent; and ≧4 as antagonistic. In order to calculate the FIC index the following calculations are performed for compounds A and B:
FIC-A=(MIC of A in combination)/(MIC of A alone) FIC-B=(MIC of B in combination)/(MIC of B alone) FIC-combination=FIC-A+FIC-B
[0123] The MIC-PHMB (MIC of PHMB in combination with EDTA(Na 4 )), a minimum concentration of PHMB, while in combination with EDTA(Na 4 ), that inhibited the growth of S. aureus in MHB was found. In order to determine the MIC-EDTA(Na 4 ) (MIC of EDTA(Na 4 ) in combination with PHMB ), a minimum concentration of EDTA(Na 4 ), while in combination with PHMB, that inhibited the growth of S. aureus in MHB was found. See FIG. 2 , 6 and 9 for results.
[0124] Thus, the FIC-PHMB is 0.4. The FIC-EDTA(Na 4 ) is 0.4. Thus, the FIC-combination is 0.4+0.4, which equals 0.80. See FIG. 9 for results. Accordingly, the combination of PHMB and EDTA(Na 4 ) unexpectedly has partial synergistic results. That is, embodiments of the combination of PHMB and EDTA(Na 4 ) provides results that are, unexpectedly, greater than the total effects of each agent operating by itself.
[0000] Checkerboard Titration Experiment— P. aeruginosa
[0125] The Checkerboard Titration method was used to assess the interactions between EDTA(Na 4 ) and PHMB. The Checkerboard Titration method is a frequently used technique where, for example, each agent (EDTA(Na 4 ) and PHMB) was tested at multiple dilutions lower than the MIC. During this experiment, EDTA(Na 4 ) and PHMB were tested in the combinations to assess if the combinations have an FIC index of <1. The following concentrations were tested:
[0000]
Concentration
Concentration PHMB
Combination
EDTA(Na 4 ) (wt %)
(PPM)
0.5 MIC + 0.5 MIC
0.125
2.5
0.4 MIC + 0.4 MIC
0.1
2
0.35 MIC + 0.35 MIC
0.0875
1.75
0.3 MIC + 0.3 MIC
0.075
1.5
0.25 MIC + 0.25 MIC
0.0625
1.25
0.125 MIC + 0.125 MIC
0.03125
0.625
[0126] The FIC-PHMB is 0.25. The FIC-EDTA(Na 4 ) is 0.25. Thus, the FIC-combination is 0.25+0.25, which equals 0.5. See FIG. 10 for results. Accordingly, the combination of PHMB and EDTA(Na 4 ) unexpectedly has full synergistic results. That is, embodiments of the combination of PHMB and EDTA(Na 4 ) provides results that are, unexpectedly, greater than the total effects of each agent operating by itself.
[0000] Checkerboard Titration Experiment— C. albicans
[0127] The Checkerboard Titration method was used to assess the interactions between EDTA(Na 4 ) and PHMB. The Checkerboard Titration method is a frequently used technique where, for example, each agent (EDTA(Na 4 ) and PHMB) was tested at multiple dilutions lower than the MIC. During this experiment, EDTA(Na 4 ) and PHMB were tested in the combinations to assess if the combinations have an FIC index of <1. The following concentrations were tested:
[0000]
Concentration
Concentration PHMB
Combination
EDTA(Na 4 ) (wt %)
(PPM)
0.5 MIC + 0.5 MIC
0.0156
0.625
0.4 MIC + 0.4 MIC
0.0125
0.500
0.35 MIC + 0.35 MIC
0.0109
0.438
0.3 MIC + 0.3 MIC
0.0090
0.375
0.25 MIC + 0.25 MIC
0.0078
0.313
0.125 MIC + 0.125 MIC
0.0039
0.156
[0128] The FIC-PHMB is 0.3. The FIC-EDTA(Na 4 ) is 0.3. Thus, the FIC-combination is 0.3+0.3, which equals 0.6. See FIG. 11 for results. Accordingly, the combination of PHMB and EDTA(Na 4 ) unexpectedly has partial synergistic results for C. albicans. That is, embodiments of the combination of PHMB and EDTA(Na 4 ) provides results that are, unexpectedly, greater than the total effects of each agent operating by itself.
[0000] Rate Kill Assay— S. aureus
[0129] As discussed above, EDTA(Na 4 ) has a MIC of <0.03% (w/v) for S. aureus and PHMB has a MIC of <1.25 PPM for S. aureus. Accordingly, the following solutions were prepared:
[0000] Composition Concentration MIC EDTA(Na 4 ) 0.015 wt % 0.5 PHMB 0.625 PPM 0.5 EDTA(Na 4 ) 0.007 wt % 0.25 PHMB 0.31 PPM 0.25 EDTA(Na 4 ) + PHMB 0.015 wt % + 0.625 PPM 0.5 + 0.5 EDTA(Na 4 ) + PHMB 0.007 wt % + 0.31 PPM 0.25 + 0.25
Each solution was then combined with S. aureus and the log recovery of the S. aureus was measured initially, after 0 hour, 1 hour, 2 hours, 3 hours and 24 hours. The difference in log recovery for the 0.5 MIC concentrations and for the 0.25 MIC concentrations is shown in FIG. 12 . The data shows that EDTA(Na 4 ) and PHMB solutions are synergistic. That is, embodiments of the combination of EDTA(Na 4 ) and PHMB provides results that are, unexpectedly, greater than the total effects of each agent operating by itself.
Rate Kill Assay— P. aeruginosa
[0130] As discussed above, EDTA(Na 4 ) has a MIC of <0.25% (w/v) for P. aeruginosa, and PHMB has a MIC of <5 PPM for P. aeruginosa. Accordingly, the following solutions were prepared:
[0000] Composition Concentration MIC EDTA(Na 4 ) 0.125 wt % 0.5 PHMB 2.5 PPM 0.5 EDTA(Na 4 ) 0.0625 wt % 0.25 PHMB 1.25 PPM 0.25 EDTA(Na 4 ) + 0.125 wt % + 2.5 PPM 0.5 + 0.5 PHMB EDTA(Na 4 ) + 0.0625 wt % + 1.25 PPM 0.25 + 0.25 PHMB
Each solution was then combined with P. aeruginosa and the log recovery of the P. aeruginosa was measured initially, after 0 hour, 1 hour, 2 hours, 3 hours and 24 hours. The difference in log recovery for the 0.5 MIC concentrations and for the 0.25 MIC concentrations is shown in FIG. 13 . The data shows that EDTA(Na 4 ) and PHMB solutions are synergistic. That is, embodiments of the combination of EDTA(Na 4 ) and PHMB provides results that are, unexpectedly, greater than the total effects of each agent operating by itself.
Rate Kill Assay— C. albicans
[0131] As discussed above, EDTA(Na 4 ) has a MIC of <0.3125% (w/v) for C. albicans, and PHMB has a MIC of <1.25 PPM for C. albicans. Accordingly, the following solutions were prepared:
[0000] Composition Concentration MIC EDTA(Na 4 ) 0.007 wt % 0.25 PHMB 0.31 PPM 0.25 EDTA(Na 4 ) 0.0035 wt % 0.125 PHMB 0.15 PPM 0.125 EDTA(Na 4 ) 0.00525 wt % 0.1875 PHMB 0.2325 PPM 0.1875 EDTA(Na 4 ) + PHMB 0.007 wt % + 0.31 PPM 0.25 + 0.25 EDTA(Na 4 ) + PHMB 0.0035 wt % + 0.15 PPM 0.125 + 0.125 EDTA(Na 4 ) + PHMB 0.00525 wt % + 0.2325 PPM 0.1875 + 0.1875
Each solution was then combined with C. albicans and the log recovery of the C. albicans was measured initially, after 0 hour, 1 hour, 2 hours, 3 hours and 24 hours. The difference in log recovery for the solutions is shown in FIG. 14 . The data does not show that EDTA(Na 4 ) and PHMB solutions are synergistic. However, the data suggests the combination is very effective against C. ablicans with PHMB being the dominant component.
[0132] The synergistic effect (via rate kill assay and checkerboard titration for P. aeruginosa ), partial synergistic effect (via checkerboard titration for S. Aureus and C. Albicans ), and synergistic effect (via rate kill assay for S. Aureus ) provides significant, practical advantages for uses of embodiments of the combination of PHMB and EDTA salt(s). Thus, embodiments of the present invention should prevent the overuse of broad-spectrum antibiotics and continued unnecessary catheter removal and replacement procedures.
pH Experiments
[0133] Further experiments were conducted to measure the effects of pH on PHMB and EDTA formulations. In order to determine MIC (minimum inhibitory concentration) and MBC (minimum bactericidal concentration) a National Committee on Clinical Laboratory Standards (NCCLS) micro-dilution procedure was followed. According to the procedure each formulation must be exposed to 6 log concentration of organism or the highest achievable concentration. In the current protocol 100 μL of MHB was mixed with 90 μL of formulation and 10 μL of log 8 organism or the highest achievable concentration. The concentration of the formulation was adjusted to obtain the required concentration in the final solution. The mixture was incubated at 37 degree C. for 16-24 hrs. After 16-24 hours the absorbance value was read at 600 nm. The obtained data was corrected by subtracting the appropriate blanks. Finally, the wells having an absorbance >0.1 were marked + and <0.1 were marked −. The +symbol indicated growth while −symbol indicates no growth. The positive growth controls must have a corrective absorbance value of >0.5 and negative controls must have a corrected absorbance value of <0.1. In cases where the positive growth controls corrected absorbance is lower than 0.5, an alternate rule is utilized which is “absorbance<than 20% of positive growth control is marked as −growth, while absorbance≧than 20% of positive growth control is marked as +growth”. pH was adjusted to the stated value using NaOH or HCl.
[0134] Staphylococcus aureus (Organism #25923), Pseudomonas aeruginosa (Organism #27853), and Candida Albicans (Organism #10231) was obtained from ATCC. PHMB was used (Avecia, Lot #1L15-038). EDTA, tetrasodium salt hydrate, was used (Alfa Aesar, Catalogue #A17385, Lot #J9570A). A 20 PPM PHMB solution in water was prepared at a pH of 7. A 8 wt % EDTA solution in water was prepared at a pH of 7. These solutions were then serially diluted as necessary to obtain the required concentrations. The MIC and MBC concentrations of PHMB and EDTA at a pH of 7 was found for each of S. aureus, P. aeruginosa, and C. albicans. See FIGS. 15-20 for results.
[0135] Based on the above, a further experiment conducted was a screening experiment using checkerboard titration to assess if the combinations at a pH of 7 fall within a range having an FIC index value of ≦1. The method used was a NCCLS micro-dilution procedure. The results of this experiment are shown in FIGS. 21-23 . Based on the results the FIC index for PHMB and EDTA at a pH of 7 is 0.6 for S. aureus, 0.5 for P. aeruginosa and greater than 1 for C. albicans.
Anticoagulant Experiments
[0136] Experiments were conducted to assess the anticoagulant capacities of PHMB, EDTA and combinations of PHMB and EDTA via a Prothrombin Time (PT) Assay. A PT assay (TM-4339-063) was conducted using a Coagulation Analyzer to obtain PT instead of manually recording the PT.
[0137] Tetrasodium EDTA (TEDTA) was used (Alfa Aesar, Catalog #A17385, Lot #J9570A). PHMB was used (Arch Biocides, Catalogue #84312, Lot #1L15-038). TriniCHECK 1 (Normal Control) was used (Trinity Biotech). TriniCHECK 2 (Abnormal Control) was used (Trinity Biotech). A KC4 Amelung Coagulizer was used (Trinity Biotech).
[0138] FIG. 24 shows the results (raw data) of the PT assay. The concentrations stated in the concentration column are the final concentrations of the reagents. TriniCHECK 1 is a normal control that provides the PT time in the range of what a normal blood sample would take to coagulate. TriniCHECK 2 is an abnormal control that provides the PT time above the range of what a normal blood sample would take to coagulate. INR (International Normalized Ratio) is a system established by the World Health Organization (WHO) and the International Committee on Thrombosis and Hemostasis for reporting the results of blood coagulation (clotting) tests. INR is calculated as:
[0000] INR =( PT test sample /PT normal control ) ISI
[0000] ISI (International Sensitivity Index) indicates the sensitivity of individual thromboplastin. The value of ISI utilized herein was 1.89.
[0139] FIG. 25 shows the results (processed data) of the PT assay. All the PTs greater than 3×the TriniCHECK 1 (normal control) were replaced with 32 seconds. This was done for the following reasons: Instrument used does not provide reproducible readings at PTs greater than 45 seconds; PTs greater than 3×the normal control results in INR greater than 6 if the ISI is 1.89. Any INR value higher than 5.5 indicates very high anticoagulant capacity and any higher value is of very little or no clinical significance; and for better assessment of data.
[0140] FIG. 26 shows the graph of the International Normalized Ratio (INR) for TEDTA from a Prothrombin Time (PT) Assay. From FIG. 26 it is evident that (within the tested range) that at a concentration of TEDTA of 4 wt %, the INR is greater than 7.25.
[0141] FIG. 27 shows the graph of the International Normalized Ratio (INR) for PHMB from a Prothrombin Time (PT) Assay. From FIGS. 24 , 25 & 27 is it evident that (within the tested range) than an increase in concentration of PHMB results in no significant increase in INR.
[0142] FIG. 28 shows the graph of the International Normalized Ratio (INR) for combined TEDTA and PHMB formulations from a Prothrombin Time (PT) Assay. From FIG. 28 , and comparing results from FIGS. 26 and 27 , it is evident that (within the tested range) that the addition of PHMB does not significantly promote or enhance the anticoagulant activity of TEDTA, but also does not negatively affect the anticoagulant activity of TEDTA. Accordingly, TEDTA (4 wt %) mixed with PHMB at 50, 75 or 100 ppm provides very good anticoagulant activity.
[0143] From the foregoing, it should be clear that the present disclosure may be embodied in forms other than those discussed above; the scope of the present disclosure should be determined by the following claims and not the detailed discussion presented above.
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Disinfectant compositions comprising PHMB and EDTA salt(s) are disclosed. The disinfectant compositions have also demonstrated activity as enhanced, fast acting catheter lock/flush solutions. They are safe for human and medical uses and may be used as prophylactic preparations to prevent infection, or to reduce the proliferation of and/or eliminate existing or established infections.
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RELATED APPLICATIONS
This application claims priority to Taiwan Application Serial Number 95133753, filed Sep. 12, 2006, which is herein incorporated by reference.
The present application is a Divisional of U.S. application Ser. No. 11/692,234, filed Mar. 28, 2007, the disclosure of which is hereby incorporated by reference herein in its entirety.
This application is also is also related to concurrently filed U.S. Divisional Applications titled “TV TUNER AND THE MANUFACTURING METHOD THEREOF” which are also Divisionals of U.S. application Ser. No. 11/692,234.
BACKGROUND
1. Field of Invention
The present invention relates to a TV tuner and a manufacturing method thereof. More particularly, the present invention relates to an ultra high frequency/very high frequency TV tuner.
2. Description of Related Art
A TV tuner plays an important role in the digital TV, a Set Top Box and a portable transmitting/receiving communication system. The TV tuner is used to amplify the received radio frequency (RF) signal, select the desired signal and filter out the undesired signal to prevent undesired signals affecting the desired ones. After that, the TV tuner lowers the filtered RF signal to an Intermediate Frequency signal.
Because the digital TV needs to be portable, the demands for small digital TVs has increased. However, the air coils used in the TV tuner require a lot of space and need to be plugged in by human hands, which increases the cost and makes portability difficult.
For the forgoing reasons, there is a need for a new TV tuner for a small, portable digital TV.
SUMMARY
According to one embodiment of the present invention, a TV tuner having an Ultra High Frequency (UHF) tracking filter, a UHF matching circuit and a single conversion Tuner IC, characterized in that the UHF tracking filter includes at least one first Low-Temperature Co-fired Ceramics (LTCC) inductor, a first varactor diode and a fine-tune capacitor electrically connected to determine the maximum gain frequency of the UHF tracking filter; the UHF matching circuit includes at least one second LTCC inductor, a second varactor diode and a capacitor electrically connected to determine the maximum gain frequency of the UHF matching circuit.
According to another embodiment of the present invention, a TV tuner having a Very High Frequency (VHF) tracking filter, a VHF matching circuit and a single conversion Tuner IC, characterized in that the VHF tracking filter includes at least one first LTCC inductor, a first varactor diode and a fine-tune capacitor electrically connected to determine the maximum gain frequency of the VHF tracking filter; the VHF matching circuit includes at least one second LTCC inductor, a second varactor diode and a capacitor electrically connected to determine the maximum gain frequency of the VHF matching circuit.
According to another embodiment of the present invention, a method for manufacturing a TV tuner which has a UHF tracking filter, a UHF matching circuit and a single conversion Tuner IC, characterized in that using LTCC inductors in the UHF tracking filter and the UHF matching circuit to determine the maximum gain frequency; tuning the single conversion Tuner IC for a tuned-voltage, in which the tuned-voltage determines the capacitances of a first varactor diode and a second varactor diode of the UHF tracking filter and the UHF matching circuit respectively; and tuning the capacitance of a fine-tune capacitor of the UHF tracking filter and the inductance of the LTCC inductor of the UHF matching circuit to determine the maximum gain frequency of the UHF tracking filter and the UHF matching circuit.
According to another embodiment of the present invention, a method for manufacturing a TV tuner which has a Very High Frequency (VHF) tracking filter, a VHF matching circuit and a single conversion Tuner IC, characterized in that using LTCC inductors in the VHF tracking filter and the VHF matching circuit to determine the maximum gain frequency; tuning the single conversion Tuner IC for a tuned-voltage, wherein the tuned-voltage determines the capacitances of a first varactor diode and a second varactor diode of the VHF tracking filter and VHF matching circuit respectively; and tuning the capacitance of a fine-tune capacitor of the VHF tracking filter and the inductance of the LTCC inductor of the VHF matching circuit to determine the maximum gain frequency of the VHF tracking filter and the VHF matching circuit.
It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a TV tuner according to one embodiment of the present invention;
FIG. 2A is an Ultra High Frequency (UHF) tracking filter according to one embodiment of present invention;
FIG. 2B is the frequency response of the UHF tracking filter according to one embodiment of present invention;
FIG. 3A is a UHF matching circuit according to one embodiment of present invention;
FIG. 3B is the frequency response of the UHF matching circuit according to one embodiment of present invention;
FIG. 4A is a Very High Frequency (VHF) tracking filter according to one embodiment of present invention;
FIG. 4B is the frequency response of the VHF tracking filter according to one embodiment of present invention;
FIG. 5A is a VHF matching circuit according to one embodiment of present invention;
FIG. 5B is the frequency response of the VHF matching circuit according to one embodiment of present invention; and
FIG. 6 is a single conversion Tuner IC according to one embodiment of present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
FIG. 1 is a TV tuner according to one embodiment of the present invention. The TV tuner includes an antenna 101 , a pre-amplifier 103 , an Ultra High Frequency (UHF) tracking filter 105 , two second amplifiers 107 and 113 , a UHF matching circuit 109 , a Very High Frequency (VHF) tracking filter 111 , a VHF matching circuit 115 and a single conversion Tuner IC 117 .
The antenna 101 is electrically connected to the pre-amplifier 103 , and the pre-amplifier 103 is electrically connected to the UHF tracking filter 105 and the VHF tracking filter 111 . The UHF tracking filter 105 , the second amplifier 107 and the UHF matching circuit 109 are electrically connected, and the VHF tracking filter 111 , the second amplifiers 113 and the VHF matching circuit 115 are also electrically connected. In addition, the UHF matching circuit 109 and the VHF matching circuit 115 are electrically connected to the single conversion Tuner IC 117 . The UHF tracking filter 105 , the UHF matching circuit 109 , the VHF tracking filter 111 and the VHF matching circuit 115 use LTCC inductors instead of air coils.
FIG. 2A is the UHF tracking filter 105 according to one embodiment of the present invention. The UHF tracking filter 105 includes a first varactor diode 213 a , a fine-tune capacitor 215 a and a first LTCC inductor 209 a . The first end of the first varactor diode 213 a is connected to the first end of the fine-tune capacitor 215 a , the first end of the first LTCC inductor 209 a is electrically connected to the second end of the fine-tune capacitor 215 a , the second end of the first LTCC inductor 209 a is electrically connected to the second end of the first varactor diode 213 a . In addition, capacitors 201 a , 203 a , 211 a and the LTCC inductors 205 a and 207 a are electrically connected to the first varactor diode 213 a and the first LTCC inductor 209 a.
FIG. 2B is the frequency response of the UHF tracking filter 105 . Because the capacitances of the first varactor diode 213 a and the fine-tune capacitor 215 a are inversely proportional to the frequency response of the UHF tracking filter 105 , such that the maximum gain frequency of the UHF tracking filter 105 can be tuned by tuning the capacitance of the first varactor diode 213 a or the fine-tune capacitor 215 a . For example, if the capacitances of the first varactor diode 213 a and fine-tune capacitor 215 a increase, the frequency response of the UHF tracking filter 105 decreases from the solid line 201 b to the dotted line 203 b . As a result, the maximum gain frequency of the UHF tracking filter 105 decreases from 205 b to 207 b.
FIG. 3A is the UHF matching circuit 109 according to one embodiment of the present invention. The UHF matching circuit 109 includes a second LTCC inductor 305 a , a second varactor diode 313 a and a capacitor 307 a . The first end of the second varactor diode 313 a is electrically connected to the first end of the capacitor 307 a , the first end of the second LTCC inductor 305 a is electrically connected to the second end of the second varactor diode 313 a , and the second end of the second LTCC inductor 305 a is electrically connected to the second end of the capacitor 307 a . In addition, capacitors 303 a , 309 a , 311 a and resistor 301 a are electrically connected to the second LTCC inductor 305 a , the second varactor diode 313 a and the capacitor 307 a.
FIG. 3B is the frequency response of the UHF matching circuit 109 . Because the inductance of the second LTCC inductor 305 a and the capacitance of the second varactor diode 313 a are inversely proportional to the frequency response of the UHF matching circuit 109 , such that the maximum gain frequency of the UHF matching circuit 109 can be tuned by tuning the inductance of the second LTCC inductor 305 a or the capacitance of second varactor diode 313 a . For example, If the inductance of the second LTCC inductor 305 a or the capacitance of the second varactor diode 313 a increases, the frequency response of the UHF matching circuit 109 decreases from the solid line 301 b to the dotted line 303 b . As a result, the maximum gain frequency decreases from 305 b to 307 b.
FIG. 4A is the VHF tracking filter 111 . The VHF tracking filter 111 includes a first LTCC inductor 405 a , a first varactor diode 413 a and a fine-tune capacitor 415 a electrically connected. In addition, there are still other capacitors 401 a , 411 a and other inductors 403 a , 407 a electrically connected to the first varactor diode 413 a and the first LTCC inductor 405 a.
FIG. 4B is the frequency response of the VHF tracking filter 111 . Because the capacitances of the fine-tune capacitor 415 a and the first varactor diode 413 a are inversely proportional to the frequency response of the VHF tracking filter 111 , such that the maximum gain frequency of the VHF tracking filter 111 can be tuned by tuning the capacitances of the fine-tune capacitor 415 a and the first varactor diode 413 a.
If the capacitances of the fine-tune capacitor 415 a or the first varactor diode 413 a increases, the frequency response of the VHF tracking filter 111 decreases from the solid line 401 b to the dotted line 403 b , such that the maximum gain frequency decreases from 405 b to 407 b . On the contrary, if the capacitances of the fine-tune capacitor 415 a or the first varactor diode 413 a decreases, the frequency response of the VHF tracking filter 111 increases.
FIG. 5A is the VHF matching circuit 115 . The VHF matching circuit 115 includes a second LTCC inductor 503 a , a second varactor diode 509 a and a capacitor 507 a . The first end of the second varactor diode 509 a is electrically connected to the first end of the capacitor 507 a , the first end of the second LTCC inductor 503 a is electrically connected to second end of the capacitor 507 a . In addition, the capacitor 501 a and LTCC inductor 505 a are electrically connected to the second LTCC inductor 503 a and the capacitor 507 a.
FIG. 5B is the frequency response of the VHF matching circuit 115 . Because the inductance of the second LTCC inductor 503 a is proportional to the frequency response of the VHF matching circuit 115 , so the maximum gain frequency can be tuned by tuning the inductance of the second LTCC inductor 503 a . If the inductance of the second LTCC inductor 503 a increases, the frequency response moves from the solid line 505 b to the dotted line 507 b , as a result, the maximum gain frequency increase from the solid line 501 b to the dotted line 503 b.
FIG. 6 is the single conversion Tuner IC 117 according to one embodiment of present invention. The single conversion Tuner IC 117 includes a third varactor diode 615 , a third fine-tune capacitor 617 , a third variable-capacitor 613 , a third LTCC inductor 611 and a third resistor 621 , in which the third fine-tune capacitor 617 is connected in parallel to the third varactor diode 615 . The first end of the third variable-capacitor 613 is electrically connected to the first end of the third varactor diode 615 and the first end of the third fine-tune capacitor 617 . The first end of the third LTCC inductor 611 is electrically connected to the second end of the third variable-capacitor 613 . The second end of the third LTCC inductor 611 is electrically connected to the second end of the third varactor diode 615 and the second end of the third fine-tune capacitor 617 .
The first end of the third resistor 621 is electrically connected to the first ends of the third varactor diode 615 , the third fine-tune capacitor 617 and the third variable-capacitor 613 , the second end of the third resistor 621 is electrically connected to a tuned-voltage generating terminal 639 . In addition, the capacitors 601 , 603 , 605 , 607 and 609 are electrically connected to the third varactor diode 615 , the third fine-tune capacitor 617 , the third variable-capacitor 613 , the third LTCC inductor 611 and the resistor 619 .
The third variable-capacitor 613 tunes the tuned-voltage such that the tuned-voltage falls within the range of 0 volts to 30 volts, then the third fine-tune capacitor 617 tunes the tuned-voltage slightly. The tuned-voltage tunes the capacitances of the first varactor diode 213 a and second varactor diode 313 a of the UHF tracking filter 105 and UHF matching circuit 109 respectively. If the tuned-voltage increases, the capacitances of the first varactor diode 213 a and the second varactor diode 313 a decrease.
The single conversion Tuner IC 117 further includes a third varactor diode 629 , a third fine-tune capacitor 631 , a third variable-capacitor 633 , a third LTCC inductor 627 and a third resistor 635 . The first end of the third LTCC inductor 627 is electrically connected to the first end of the third variable-capacitor 633 . The second end of the third LTCC inductor 627 is electrically connected to the second end of the third varactor diode 629 and the second end of the third fine-tune capacitor 631 .
The second end of the third variable-capacitor 633 is electrically connected to the second end of the third varactor diode 629 and the second end of the third fine-tune capacitor 631 . The first end of the third resistor 635 is electrically connected to the second end of the third variable-capacitor 633 , the second end of the third resistor 635 is electrically connected to a generating terminal of the tuned-voltage 639 with very high frequency.
The third variable-capacitor 633 tunes the tuned-voltage such that the tuned-voltage falls within the range of 0 volts to 30 volts, then the third fine-tune capacitor 631 tunes the tuned-voltage slightly. The tuned-voltage tunes the capacitances of the first varactor diode 413 a and second varactor diode 509 a of the VHF tracking filter 111 and VHF matching circuit 115 respectively. If the tuned-voltage increases, the capacitances of the first varactor diode 413 a and the second varactor diode 509 a decrease.
According to the embodiments, the tracking filters and matching circuits of the TV tuner use LTCC inductors instead of air coils, which reduces the volume of the TV tuner such that the digital TV can be portable. In addition, the plugging process of the air coils done by human hands can be omitted, which reduces the cost.
Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 USC §112, ¶6. In particular, the use of “step of” in the claim herein is not intended to invoke the provisions of 35 USC §112, ¶6.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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A TV tuner includes an Ultra High Frequency (UHF)/Very High Frequency (VHF) tracking filter, an UHF/VHF matching circuit and a single conversion Tuner IC. The UHF/VHF tracking filter includes a first Low-Temperature Co-fired Ceramics (LTCC) inductor, a first varactor diode and a fine-tune capacitor electrically connected to determine the maximum gain frequency of the UHF/VHF tracking filter. The UHF/VHF matching circuit includes a second LTCC inductance, a second varactor diodes and a fine-tune capacitor electrically connected to determine the maximum gain frequency of the UHF/VHF matching circuit.
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BACKGROUND OF THE INVENTION
This invention is related to a device for selecting a laminate cam for sewing machines equipped with laminate zig zag pattern cams and laminate feed cams with which are engaged a zig zag cam follower and a feed cam follower, respectively, so that a laminate zig zag pattern cam and a laminate feed cam can be selected to effect the stitching of composite patterns depending upon the selections.
A linking system, gear system or the like are usually employed for the stitch pattern-indicating mechanism, zig zag pattern cam-selection mechanism and the feed cam-selection mechanism used for the sewing machines. With such known systems, however, even if a control dial for selection provided at the front surface of the sewing machine is turned in a given direction, the follower lever moves only in one direction. Therefore, to obtain a certain desired number of stitch patterns including composite patterns, it is necessary to provide zig zag pattern cams of a number equal to the number of stitch patterns as well as feed cams of a number needed for obtaining composite patterns.
SUMMARY OF THE INVENTION
The object of this invention is to provide a device for selecting a laminate cam for use in sewing machines, which enables composite patterns to be materialized by way of a simple mechanism and easy operation without requiring such complicated mechanisms.
To achieve this object, the device of this invention is provided with a disk cam, the front surface of which having a spiral groove to select a stitch pattern by means of a pointer needle attached to a lever having a pin which engages said groove, and the back surface of which disk cam having two cam-selection grooves, i.e., a zig zag pattern cam-selection groove and a feed cam-selection groove, the former groove being interlocked to a cam follower and the latter groove being interlocked to a feed cam follower. In addition, according to this invention, these cam-selection grooves are formed in particular shapes, so that a combination of two or more pattern cams is allowed for a single feed cam. By this setup of this invention, an increased number of composite patterns can be obtained as compared to the prior arts using the same number of cams.
DESCRIPTION OF THE DRAWINGS
THe drawings show an embodiment of this invention, in which:
FIG. 1 is a front view showing a mechanism for selecting the stitch patterns;
FIG. 2 is a plan view showing a mechanism for selecting zig zag pattern cams and a mechanism for selecting feed cams;
FIG. 3 is a perspective view showing in a disassembled manner the relation among the members shown in FIG. 2, laminate cams and follower levers;
FIG. 4 is a plan view showing a disk cam and a stitch pattern-selection groove formed on the front surface thereof;
FIG. 5 is a plan view showing the disk cam, and a zig zag pattern cam-selection groove and a feed cam-selection groove formed on the back surface thereof;
FIG. 6 is a diagram showing in the form of an expansion plan the distances of the zig zag pattern cam-selection groove and the feed cam-selection groove formed on the back surface of the disk cam from the center of the cam, and the relation among the groove and stitch patterns, position of pattern-selection groove on the disk cam, zig zag pattern cams and feed cams; and
FIG. 7 is a diagram showing the relation between the positions in the zig zag pattern cam-selection groove and the zig zag pattern cams for obtaining various stitch patterns, and the relation between the positions in the feed selection cam groove and the feed cams, in the same manner as in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention with reference to the accompanying drawings will now be described.
As shown in FIGS. 1 to 3, a disk cam 2 is rotatably mounted on a shaft 3 which is secured at the central part on the front surface of a rectangular mounting plate 1 which is installed in a sewing machine housing. On the front surface of the disk cam 2 is formed a spiral pattern-selection groove 4 as shown in detail in FIG. 4. On the disk cam 2 is integrally formed a control dial 5 so that it can be operated on the front surface of the sewing machine. At a lower part on the front surface of the mounting plate 1 is also secured an L-shaped bracket 6. To the upper part of the bracket 6 is pivoted an end of a circular pointer needle operation lever 7 by means of a shouldered screw 8, and the other end of said level 7 is rotatably linked to a vertically disposed pointer needle member 10 via a link 9. On the upper surface at the central part of the pointer needle operation lever 7 is secured a pin 11 which engages the spiral pattern selection groove 4 formed on the front surface of the disk cam 2. Further, at the upper part on the front surface of the mounting plate 1 is mounted a planar slide plate 12 having rack 12' at its upper part in parallel with said mounting plate 1 and maintaining a clearance from the front surface of the mounting plate 1. A pointer needle member 10 is allowed to slide along the clearance between the slide plate 12 and the mounting plate 1. The upper edge of the pointer needle member 10 is folded to overlap the upper edge of the slide plate 12, and a spring 13 attached to one end of the pointer needle member 10 is engaged with the rack 12' to eliminate the looseness that may develop when a pointer needle 14 formed integrally together with the pointer needle member 10 is shifted. On the front surface of the slide plate 12 is installed a pattern plate 15 describing stitch patterns a, b, c, etc., which will appear on the front surface of the sewing machine. The pointer needle 14 moves along the upper edge of the pattern plate to indicate any one of the stitch patterns a, b, c, etc. To the bracket 6 is attached an end of a disk cam spring 16, and the other end 16' of said spring 16 is formed in a V-shape to engage grooves 18 of the same number as zig zag pattern cams 52 which will be mentioned later, said grooves 18 being formed on the outer periphery of the disk cam 2, thereby to determine the positions of the stitch patterns a, b, c, etc. selected by the pointer needle 14, as well as to simultaneously determine the positions of cam followers 61, 71 that will be mentioned later. Further, on the back surface of the disk cam 2 rotatably mounted on the mounting plate 1 are formed two spiral grooves, i.e., one being a zig zag pattern cam-selection groove 20 and the other being a feed cam-selection groove 21 as shown in FIG. 5. In the mounting plate 1 are further vertically formed two elongated groove 30, 31 that are in parallel with a cam shaft 50 which will be mentioned later. To the elongated grooves 30, 31 is fitted a rectangular operation plate 32 in a manner to slide in said elongated grooves 30, 31 by means of flanged pins 33, 33 that are fastened from the back surface of the mounting plate 1. Further, at the upper part on the front surface of the mounting plate 1 is rotatably attached an operation plate lever 35 by means of a shouldered screw 34, and a pin 36 attached to the other end of the operation plate lever 35 is slidably engaged with an elongated groove 37 formed on the operation plate 32 in the direction at right angles to said elongated grooves 30, 31. A pin 38 secured at a middle part on the front surface of the lever 35 engages the zig zag pattern cam-selection groove 20 formed on the back surface of the disk cam 2. Further, onto the back surface of the operation plate 32 is secured a pin 39 which penetrates through the elongated groove 30 formed in the mounting plate 1; onto said pin 39 is rotatably mounted a positioning latch 40 on the back surface of the mounting plate 1. A shaft part 41' of a flanged positioning pin 41 penetrating through the elongated groove 30 from the back surface of the mounting plate 1 is secured onto the back surface of the operation plate 32, and to said shaft part 41' is fitted a base part of a wire spring 42. One end 42' of the wire spring 42 is hooked to an arm 40' of the latch 40, and the other end 42" is hooked to a part 32' of the operation plate 32, so that an end 40" of the positioning latch 40 will engage a rack 43' formed on one side of a positioning plate 43 which is adjustably mounted on the back surface of the mounting plate 1 in parallel with the elongated groove 30.
To the cam shaft 50 supported on the machine housing, on the other hand, are fitted a cam shaft gear 51, several laminate zig zag pattern cams 52 and several laminate feed cams 53, so that the rotation of an upper spindle (not shown) will be transmitted to the laminate zig zag pattern cams 52 and the laminate feed cams 53 via said cam shaft gear 51, in the same manner as done conventionally. A cam follower shaft 60 is mounted on the machine housing in parallel with the cam shaft 50, and to said shaft 60 is slidably mounted a cam follower 61. With a recess 61' formed at the base part of said cam follower 61 is engaged the end 41" of the positioning pin 41. The cam follower 61 has an end 61" which is always forced to come into contact with one of the laminate pattern cams 52 due to the resilient force of a spring (not shown). To the front surface of the mounting plate 1 is secured an L-shaped operation plate guide 44. The ends 32", 32" formed on the upper and lower parts on one side of the operation plate 32 are guided along said operation plate guide 44; the operation plate 32, therefore, is allowed smoothly to move along the elongated grooves 30, 31 by way of shouldered pins 33, 33.
Another elongated groove 45 is further formed in the mounting plate 1 in parallel with the elongated grooves 30, 31, and onto said elongated groove 45 is slidably mounted a slide block 46 by way of the shaft 47' of the flanged feed positioning pin 47 that is penetrated from the back surface of the mounting plate 1. Further, a slide block adjustor plate 48 having a laterally elongated hole 48' is secured at its base part to the slide block 46 by fastening a nut 48" to the shaft 47' of the positioning pin 47. A feed cam follower shaft 70 is mounted on the machine frame in parallel with the cam shaft 50, and on said follower cam shaft 70 is slidably mounted a feed cam follower 71. With a recess 71' formed on the base part of said feed cam follower 71 is engaged an end 47" of the positioning pin 47. The end 71" of said feed cam follower 71 is always forced to come into contact with one of the laminate feed cams 53 due to the force of a spring (not shown), or is located at a position (below the feed cams in the drawing) at which it does not engage the feed cams 53. Moreover, on the front surface of the mounting plate 1 is rotatably mounted an L-shaped slide block lever 81 which is held at its one end by a stepper screw 80. A pin 82 secured on the back surface of the lever 81 engages a laterally elongated hole 48' of the slide block adjustor plate 48, and a pin 83 secured on the front surface at the other end engages the feed cam-selection groove 21 formed on the back surface of the disk cam 2. As shown in the expansion plans of selection grooves 20, 21 of FIG. 6, according to the embodiment of this invention, the spiral of the zig zag pattern cam-selection groove 20 defines a distance to the center which gradually reduces as it approaches toward the center, and which increases from a given point, and which reduces again gradually as the groove advances toward the center. For example, the distance is equal at positions m, m' and m" on the groove 20. The spiral of the feed cam-selection groove 21, on the other hand maintains an equal distance to the center over some part of the groove, and gradually reduces the distance to the center after a given point is passed on the groove 21.
The device according to this invention is constructed as mentioned above. The operation of the device is explained below.
First, when the patterns are to be selected, the cam follower 61 and the feed cam follower 71 which are forced to come into contact with the laminate zig zag pattern cams 52 and the laminate feed cams 53 by the action of springs (not shown), are retracted via the cam follower shaft 60 and the feed cam follower shaft 70 so that they are released from contact with the cams. The mechanism for the above follower retraction operation, however, is not included in the scope of this invention, and is not illustrated here.
To obtain desired stitch patterns, a control dial 5 attached to a disk cam 2 is turned so that the pointer needle operation lever 7 engaged via a pin 11 with the spiral pattern-selection groove 4 formed on the front surface of the disk cam 2 is moved via said pin 11 with a shouldered screw 8 as a fulcrum, and the pointer needle member 10 is shifted on the slide plate 12 via a link 9, thereby to set the pointer needle 14 at one of the stitch patterns a, b, c, etc. described on the pattern plate 15. As mentioned earlier, the grooves 18 have been formed on the outer periphery of the disk cam 2, and to one of said grooves 18 is engaged the end 16' of the disk cam spring 16. The control dial 5 can be easily turned by hand against the force of the spring 16. and said engagement helps the pointer needle 14 to determine a position of the stitch patterns a, b, c, etc.
The operation of the mchanism for selecting the zig zag pattern cams will now be described.
By turning the control dial 5, the control plate lever 35 having pin 38 engaged with the zig zag pattern cam-selection groove 20 formed on the back surface of the disk cam 2, is turned with the shouldered screw 34 as a fulcrum in cooperation with the pin 11 of the pointer needle operation lever 7. Further, the pin 36 provided on the other end of the lever 35 has been engaged with the elongated groove 37 of the operation plate 32, and the operation plate 32 has been so mounted on the mounting plate 1 as to slide in the elongated grooves 30, 31 by means of flanged pins 33, 33. Therefore, if the control dial 5 is turned, the operation plate 32 moves in the up and down directions due to the action of the wire spring 42 being guided by the operation plate guide 44. To the operation plate 32 has also been attached the positioning pin 41 penetrating through the elongated groove 30 of the mounting plate 1, and the end 41" thereof has been engaged with the recess 61' of the cam follower 61. Therefore, the operation plate 32 so works that the cam follower 61 moves up and down on the cam follower shaft 60, in order that the end 61" of the cam follower 61 will select one of the laminate pattern cams 52. The positioning latch 40 engaged with the pin 39 of the operation plate 32 has its end 40" engaged due to the wire spring 42 with the rack 43' of the positioning plate 43 which is adjustably mounted on the back surface of the mounting plate 1, thereby to reliably determine the stop position of the cam follower 61.
The zig zag pattern cam-selection groove 20 has been so formed as shown by an expansion plan of FIG. 6 and is constructed as mentioned earlier. By turning the control dial 5, the pin 38 of operation plate lever 35 follows the zig zag pattern cam-selection groove 20 on the back surface of the disk cam; the distance to the center gradually reduces from point a to point n in the groove 20, whereby the operation plate 32 is lowered gradually causing the cam follower 61 to be lowered via positioning pin 41 studded on the operation plate 32. However, as the control dial 5 is turned further, the pin 38 is pushed up over the section from point n to point j', and lowered again over the section from point j' to point n", causing the cam follower 61 to perform the same operation. For instance, therefore, referring to FIG. 6, the position of point k in the selection groove 20 is the same as the positions of point k' and point k". Therefore, the end 61" of the cam follower 61 is located at a position K in the zig zag pattern cams 52.
The operation of the mechanism for selecting the feed cams will now be described.
By turning the control dial 5, the pin 11 of the pointer needle operation lever 7 and the pin 38 of the operation plate lever 35 operate together, and the pin 83 of the slide block lever 81 engaged with the feed cam-selection groove 21 on the back surface of the disk cam 2 turns with the shouldered screw 80 as a fulcrum. The slide block lever 81 has a pin 82 which is engaged with the elongated hole 48' of the slide block adjustor plate 48 which is fastened to the slide block 46 by the feed positioning pin 47. The slide block 46 is further slidably mounted on the mounting plate 1 so as to slide in the elongated groove 45, and the end 47" of the feed positioning pin 47 is engaged with the recess 71' of the feed cam follower 71. Therefore, the slide block lever 81 so works as to move the feed positioning pin 47 up and down by means of the slide block 46, whereby the feed cam follower 71 moves up and down on the feed cam follower shaft 70 so that the end 71" of the feed cam follower 71 will select one of the laminate feed cams 53.
The feed cam-selection groove 20 is as shown in expansion plans of FIG. 5 and FIG. 6. If the disk cam 2 is so turned that the pin 83 of the slide block lever 81 is located at a position off (off 1 and off 2 ) (off 1 stays at an equal distance from the center and the pin 83 does not move, but the pin 83 is moved if the groove advances from off 1 to off 2 ), the end 71" of the feed cam follower 71 is located at a position lower than the laminate feed cams 53 and does not work. However, if the disk cam 2 is further turned so that the pin 83 comes to a position X, the end 71" of the feed cam follower 71 is located on a feed cam 53-X and will maintain its position. Then, if the pin 83 comes to a position y, the end 71" of the feed cam follower 71 is located on a feed cam 53-Y.
The relationship between the pattern-selection groove 4 formed on the front surface of the disk cam 2, the zig zag pattern cam-selection groove 20 and the feed cam-selection groove 21 formed on the back surface of the disk cam 2 for obtaining desired composite stitch patterns will now be described.
For example, to obtain a stitch pattern a (see FIG. 7), a control dial 5 will be turned, so that the pin 11 of the pointer needle operation lever 7 is located at a position a of the pattern-section groove 4 and the position needle 14 indicates the stitch pattern a. At this time, the pin 38 of the operation lever 35 is located at a position "a" in the zig zag pattern cam-selection groove 20, and the end 61" of the cam follower 61 is located on a zig zag pattern cam 52-A. In this case, the pin 83 of the slide block lever 81 is located at off 1 in the feed cam-selection groove 21, and the end 71" of the feed cam follower 71 is located below (or out of engagement with) the laminate feed cam 53 and will not be influenced thereby. Therefore, only the cam follower 61 engages the zig zag pattern cams 52; a stitch pattern a is obtained without involving the function of the feed cams 53. The same operation as above will be performed to obtain stitch patterns b to m. To obtain a stitch pattern n, the pin 38 is shifted to a position "n" in the groove 20, the end 61" of the cam follower 61 is located on a zig zag pattern cam 52-N, the pin 83 of the slide block lever 81 is moved a little to a position off 2 in the feed cam-selection groove 21, the feed cam follower 71 is moved accordingly, and the end 71" thereof is raised a little. However, the end 71" is still located at a position lower than the laminate feed cams 53, and does not engage therewith. Therefore, a stitch pattern n is obtained by the zig zag pattern cam 52-N only.
Further, to obtain a stitch pattern o, by turning the control dial 5, the zig zag pattern cam-selection groove 20 gradually separates away from the center. At the point m' in the groove 20, the distance is just equal to the previous point m. Therefore, the cam follower 61 that was once lowered is raised again, and located on the zig zag pattern cam 52-M. On the other hand, the feed cam groove 21 gradually approaches the center; as the pin 83 of the slide block lever 81 comes to a position x in the cam groove, the end 71" of the feed cam follower 71 comes onto a feed cam 53-X. Therefore, the stitch pattern o is obtained by the composite functions of the zig zag pattern cam 52-M and the feed cam 53-X. In the same way, the stitch patterns p, q and r are obtained by the composite functions of the zig zag pattern cams 52-L, -J and -K, and the feed cam 53-X (in the embodiment, the point x in the feed cam-selection groove keeps the same position, and the feed cam follower 71 remains located on the same feed cam 53-X).
Then to obtain stitch patterns r, s and t, the control dial 5 is further turned. The zig zag pattern cam-selection groove 20 then gradually approaches the center, and the composite patterns are obtained by the points K", 1" and m" in the groove 21 and the point y in the cam groove 20.
As mentioned above, by so forming the spiral zig zag pattern cam-selection groove that the distance is varied with respect to the center, it is possible to obtain, for example, three stitch patterns m, o and u by a cam 52-M among many zig zag pattern cams 52 and cams X and Y among many feed cams 53. According to the above-mentioned method, it is possible to obtain many more composite stitch patterns by varying not only the shape of the zig zag pattern cam-selection groove but also varying the shape of the feed cam-selection groove.
According to this invention, as mentioned above, the stitch patterns can be selected and indicated by means fo three grooves, i.e., pattern-indication groove, zig zag pattern-selection cam groove and feed selection cam groove that are formed on the disk cam, simply by turning the control dial. Besides, the device according to this invention is very simply constructed and handled as a single module (assembly), and is further manufactured cheaply, providing highly advantageous results.
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A cam selector mechanism for sewing machines in which the followers for a stack of zig zag and work feed controlling pattern cams are positioned selectively by separate spiral linkage controlling grooves formed in a single control dial which can be manipulated from the exterior of the sewing machine in order that composite patterns of ornamental stitches can be obtained. The selector dial also influences a pattern indicating device simultaneously with cam selection.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and benefit of U.S. Provisional Application No. 62/119,534 filed on 23 Feb. 2015.
[0002] The aforementioned provisional patent application is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] None.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to the production of a foam, for example from molybdenum sulfide (MoS), and more particularly, synthesis of molybdenum sulfide (Mo x S y ) foam.
[0006] 2. Brief Description of the Related Art
[0007] There is a great demand for energy worldwide due to increases in population and economic activities in many parts of the world especially in developing countries such as China and India. The energy supply has to keep pace with energy demand. Thus, there are several options for generating energy including fossil-based fuels, solar, nuclear and wind. Many countries have plans to increase the share of renewables in the energy mix and reduce dependence on fossil fuels.
[0008] For the latter, fossil fuel-based energy generation relies mainly on natural gas due to its lesser impact on environment and high energy density. Natural gas is produced as an associated gas in oil wells or as sour gas in gas wells, which contains significant amount of hydrogen sulfide (H 2 S) and carbon dioxide (CO 2 ). When developing sour gas fields, H 2 S and CO 2 have to be removed completely before selling the gas for energy generation. In doing so, the H 2 S gas is removed by converting it to elemental sulfur through Claus process.
[0009] There is a worldwide concern about the increasing environmental effects of oil & gas production. Removal of the sulfur-containing compounds is necessary before utilizing natural gas or any other refinery products.
[0010] This large amount of sulfur should bring great motivation and interest for research in this area to come up with different applications that utilize sulfur and hence improve its marketability. One of the forms of utilization is in metal-sulfides, which have a wide range of applications in different industries. Metal sulfides contain at maximum two sulfur atoms per metal and hence have high sulfur content. It follows that with such high content, devising applications for these sulfides will be a suitable way to improve sulfur long-term marketability.
[0011] Catalytic chemical processes need materials with high active and accessible surface. MoS 2 has been the preferred material option as a catalyst for hydro-desulphurization, which is the catalytic chemical process to remove sulfur from natural gas or other refined chemical products, such as gasoline, jet fuel, kerosene, etc. The molybdenum disulfide MoS 2 used to date has a substantially two-dimensional surface, which limits the reactive surface area. One method of increasing the effectiveness of the molybdenum disulphide catalyst would therefore be to create a larger surface area. The challenge is to expand this large surface area into the third dimension.
[0012] U.S. Patent Application Publication No. U.S. 2005/0059545 (Alonso et al), granted as U.S. Pat. No. 7,223,713, teaches one method for the synthesis of MoS 2 for use as a catalyst with a large surface area. The method involves adding ammonia tetrathiomolybdate salt precursor to a precursor, having an active metal like cobalt. The precursor is decomposed under hydrothermal conditions to form a molybdenum disulfide catalyst in the form of powder, which will also contain carbon.
[0013] U.S. Patent Application Publication No. U.S. 2003/0144155 (Tenne et al) also teaches a method of manufacturing a porous matrix of molybdenum disulfide and having nanoparticles of metal chalcogenide inserted into the pores.
[0014] Most of the attempts in the past have mainly been approaches to volume applications by using MoS 2 powder. One difficulty faced with such application has been the anchoring of the particles of the MoS 2 powder into a supporting structure. The supporting structure should not, in itself be an active material, which would otherwise cause inefficiencies in the chemical catalytic process. In the past, additional catalysts and co-catalysts have been used to make MoS 2 more active, which is consistent with the industry practice of using chemical treatments instead of making physical improvements.
[0015] The literature provides many examples of previous work done with molybdenum sulfide (MoS) relying on conventional synthesis techniques. Other publications describe the improvement of those same techniques with some modifications.
[0016] Molybdenum disulfide (MoS 2 ) material has other applications in many industries, which would also benefit from an improved structure. For example, molybdenum disulfide has been used as a lubricant in various applications due to its weak van der Waals bonding between its layers. See, E. Benavente et al, “Intercalation chemistry of molybdenum disulfide,” Coordination Chemistry Reviews, vol. 224, pp.87-109, 2002. A number of different synthesis methods are known in the literature, which will now be discussed.
[0017] Sulfidation of the oxide. This method involves solid-gas chemical reaction of the corresponding oxide to produce molybdenum disulfide. It is mostly studied for the field of the hydro-treating processes, in which the molybdenum disulfide is used to enhance the hydro-treating process. The morphology of the produced molybdenum disulfide cannot be easily controlled using this synthesis method. See, P. Afanasiev, “Synthetic approaches to molybdenum sulfide materials,” C. R. Chemie, vol. 11, pp. 159-182, 2008.
[0018] Decomposition of precursors. Another method for preparing the molybdenum disulfide is through decomposition of a precursor material. The precursor material is a solid/liquid/gas that has the necessary reactants to produce the final product of molybdenum disulfide, where all reaction takes places on a substrate. This method does not involve any external reactant or process steps to get the product. The final product morphology is determined based on the precursor type and the decomposition reaction. See, for example, P. Afanasiev, “Synthetic approaches to molybdenum sulfide materials,” C. R. Chemie, vol. 11, pp. 159-182, 2008. One of the well-known species that acts as a precursor is ammonium tetrathiomolybdate, abbreviated as ATTM or ATM.
[0019] Solutions reaction. Homogenous reaction that precipitates the molybdenum disulfide as a product is another approach to synthesis the material. This method does not assure the pure products yield of MoS. Other products can be produced from this reaction, like sulfur-rich sulfide, which can be converted to the molybdenum disulfide by thermal decomposition. The slow reaction rate gives better morphology and more control on the MoS 2 .
[0020] The literature has also many examples of how the molybdenum disulfide can be produced directly through a reaction in an aqueous medium. One of the techniques is to use sonochemical synthesis. Nanostructured molybdenum sulfide with high surface area was obtained by this technique. See, M. M. Mdleleni, T. Hyeon, K. S. Suslick, “Sonochemical Synthesis of Nanostructured Molybdenum Sulfide,” Journal of the American chemical Society, vol. 120, pp. 6189-6190. 1998. The nanostructured molybdenum sulfide is prepared by irradiating a slurry solution of molybdenum hexacarbonyl and sulfur along with other chemicals under high intensity ultrasound. Analysis of the produced sample shows larger surface area in comparison to the conventional method of decomposing ammonium tetrathiomolybdate (ATTM) under Helium. Other approaches show the preparations of MoS in aqueous solution by adding surfactants producing high surface area. Metal usually not easily to form aqueous solution and requires H 2 S or alkali metal sulfides. See, P. Afanasiev, et al, “Surfactant-Assisted Synthesis of Highly Dispersed Molybdenum Sulfide,” Chem. Mater., vol. 11, pp. 3216-3219, 1999.
[0021] Surfactant-assisted preparation. This preparation method involves the addition of a surfactant to the preparation technique chosen; it could be either used in either chemical reaction or physical preparations. Surfactants are species that can be attached to the surfaces of the layered material keeping a space between them. In molybdenum sulfide preparations, the surfactant is added to separate the layer of the molybdenum sulfide and control the morphology to fit a desired application. The produced molybdenum sulfide is tested for its mechanical and chemical properties. Other approaches are based on chemical reactions by adding certain types of surfactants to the reactions mixture. See, P. Afanasiev, “Synthetic approaches to molybdenum sulfide materials,” C. R. Chemie, vol. 11, pp. 159-182, 2008.
[0022] Intercalation, exfoliation and restacking techniques. Intercalation can be defined as a process of inserting guest molecules between layered materials in order to ease the separation of the layered materials into single layers. There are two methods for the intercalation step: intercalation of lithium and intercalation of molecular species. The first method is performed by the insertion of alkali metals into the molybdenum sulfide layers such as lithium (Li). It is referred to as a direct intercalation process, which is commonly used rather than other metals. Some work was done to examine intercalation with other alkali metal, see, E. Benavente et al, “Intercalation chemistry of molybdenum disulfide,” Coordination Chemistry Reviews, vol. 224, pp. 87-109, 2002, yet the focus is on Li as it has potential application in high power Li batteries. The process can be described as an ion-electron transfer reaction. Intercalation leads to structural, thermodynamics and reactivity changes in the molybdenum sulfide. Lithium can be intercalated into the molybdenum sulfide layers by two methods: chemical and electrochemical methods. The chemical method is more commonly used, which is carried out by dispersing the molybdenum sulfide in a solution of butyl lithium and organic solvent. See, M. B. Dines, “Lithium intercalation via n-Butylithium of layered transition metal dichalcogenides,” Material Research Bulletin, vol. 10 pp. 287-291, 1975. FIG. 1 shows a schematic of the process of intercalation by lithium. See, E. Benavente et al, “Intercalation chemistry of molybdenum disulfide,” Coordination Chemistry Reviews, vol. 224, pp. 87-109, 2002.
[0023] The second method is the intercalation of a molecular species, which is similar to the first method, except that the second method involves the insertion of a compound between the layers. The intercalation step is followed by exfoliation. This step is aimed to remove the molecular species added by a solution that dissolves or react with the molecular species and separate the layers. FIG. 2 adopted from P. Afanasiev, “Synthetic approaches to molybdenum sulfide materials,” C. R. Chemie, vol. 11, pp. 159-182, 2008, shows how this is done. The final step involves adding certain surfactant that fit the material to hold the final structure.
[0024] Other than the well-understood approach of Lithium intercalation, different types of guest species have been reported in the literature. Different types of guest species can be intercalated into the molybdenum sulfide, such as polymers, molecular donor, cationic species or organometallic species. A recent work shows that colloidal polymer suspensions of guest species could intercalate the molybdenum sulfide. See, R. Bissessur, P. K. Y. Liu, “Direct insertion of polypyrrole into molybdenum disulfide,” Solid State Ionics, vol. 177, pp. 191-196, 2006.
[0025] Another work shows the molybdenum sulfide as thin layers in an electronic application. A thin sheet of molybdenum sulfide has been deposited on insulating substrates. This thin sheet is highly crystalline and has high electron mobility, which matches the properties of the micro-mechanical exfoliated sheets from MoS2 crystals. K. Liu et al, “Growth of Large-Area and Highly Crystalline MoS2 Thin Layers on Insulating substrates, Nano letters, vol. 12, pp. 1538-1544. 2012.
[0026] An Example of preparation of MoS 2 /polyvinyl alcohol nanocomposite is known from K. Zhou, S. Jiang, C. Bao, L. Song, B. Wang, G. Tang, et al., “Preparation of poly(vinyl alcohol) nanocomposites with molybdenum disulfide (MoS 2 ): structural characteristics and markedly enhanced properties,” RCS Advances, vol. 2, 2012. The synthesis started with commercial material of MoS 2 solvothermal step with butyl lithium (a known chemical for getting Li ions inside the sheets of MoS 2 ) which produces Li x MOS 2 . The exfoliated MoS 2 layers were produced from hydrolysis and ultrasonication of Li x MoS 2 to produce a clean colloidal suspension with MoS 2 layers separated. The layers were then added to polyvinyl alcohol polymer solution by solvent blending method, which produces the final mixture that was dried to get the film nanocomposite.
[0027] Uses of the molybdenum disulfide catalyst are known, for example, from U.S. Pat. No. 8,673,805 (Anand et al) which teaches the conversion of sugar alcohol to a hydrocarbon.
SUMMARY OF THE INVENTION
[0028] In a preferred embodiment, the present invention is a method for the synthesis of molybdenum disulphide foam from a film, wherein the porosity of the foam can be controlled. The benefit of being able to control the porosity is to adapt the porosity to various applications of the molybdenum disulfide foam and its specific requirements. In particular, the prior art does not discuss monolithic molybdenum disulphide structures where cavities are interconnected to create a large processing surface area.
[0029] Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a preferable embodiments and implementations. The present invention is also capable of other and different embodiments and its several details can be modified in various obvious respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description and the accompanying drawings, in which:
[0031] FIG. 1 is a diagram showing intercalation of the molybdenum sulfide with Lithium and steps of intercalation, exfoliation and restacking of molybdenum sulfide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The preferred embodiments of the inventions are described with reference to the drawings.
[0033] The inventors have recognized from study of the literature that a new form of the molybdenum sulfide would provide new uses and applications for molybdenum sulfide. The method presented in this disclosure aims to achieve the following set of objectives:
1. Prepare porous molybdenum sulfide Mo x S y foam. The foam size is dependent of the container, but we produced in lab foam size of 1 cm by 3 cm with a thickness of 0.1 centimeter. 2. Screen different preparation methods that control porosity. 3. Characterize the material using several methods including structural, compositional and thermal properties. 4. The porous Mo x S y created was used in a hydro-desulfurization application.
[0038] The present disclosure teaches a method of synthesizing a foam made from molybdenum sulfide with interconnected cavities. The foams created have typically a physical size of 3×2 cm and a thickness of 0.1 cm, but this is not limiting of the invention.
[0039] It is believed that similar methods can be used for other sulfides, for example tungsten sulfide, as well as for boron nitride and graphene.
[0040] Two methods for the synthesis of the foam will now be described.
[0041] Top-down approach. The method is summarized in FIG. 1 .
[0042] This synthesis method starts by using molybdenum sulfide in the form of a solid material. An intercalation species used to intercalate the molybdenum sulfide material in the presence of other species, such as laponite or polymers such as PVOH. Other intercalation species could be positive ions of alkylammonium cations, which would enhance the final structure of the molybdenum sulfide foam (see A. S. Golub, Y. V. Zubavichus, Y. L. Slovokhotov, Y. N. Novikov, and M. Danot, “Layered compounds assembled from molybdenum disulphide single-layer and alkyammonium cations,” Solid State Ionics, vol. 128, pp. 151-160, 2000.).
Another example involves direct insertion of polypyrrole into the Li-exfoliated sheets of MoS 2 (see R. Bissessur and P. K. Y. Liu, “Direct insertion of polypyrrole into molybdenum disulfide,” Solid State Ionics, vol. 177, 2006) Non-limiting examples of intercalation species that can be used include, but are not limited to organic materials, inorganic materials and organometallic compounds. It is known that alkali metals show good performance for intercalation of layered material and in one non-limiting example lithium was used. Further examples are listed in S. Wang, C. An, and J. Yuan, “Synthetic Fabrication of Nanoscale MoS2-Based Transition Metal Sulfides,” Materials, vol. 3, pp. 401-433, 2010.
[0044] FIG. 1 shows the intercalation of a stack of the molybdenum sulfide layers using Lithium ions as an intercalating species. Exposure of the lithium-molybdenum sulfide species to water leads to exfoliation of the molybdenum sulfide layers. A spacer, for example but not limited to, polyvinyl alcohol is used. This is used to retain a space between the exfoliated layers. It will be appreciated that other water soluble molecules and macromolecules could be use.
[0045] Bottom-up approach. This synthesis method starts by a precursor material, which is converted later to the molybdenum sulfide foam. One of the known precursors is ammonium tetrathiomolybdate (abbreviated ATTM/ATM). A mixture of Laponite and ATTM was made with equal compositions of both species. The aqueous solution of the species was freeze dried, before heated at several temperatures, to decompose to molybdenum sulfide.
[0046] Instead of Laponite, it would be possible to use naturally-occurring montmorillonite or smectite, for example.
[0047] The present invention has multiple advantages over prior approaches:
Less volume/space required to achieve same effect as conventional solutions Increased efficiency if applied for liquid and gas processes Besides hydro-desulphurization other fields off applications are apparent: sense and control, structural materials
EXAMPLES
Example 1
Synthesis Methods of MoS 2 Foam
[0051] The following chemicals were used. Poly (vinyl alcohol) 99+% hydrolyzed (from Sigma-Aldrich), molybdenum (IV) sulfide powder <2 micro 99% (from Sigma-Aldrich), Ammonium tetrathiomolybdate (ATTM) 99.97% metal basis (from Sigma-Aldrich) along with commercially available laponite clay powder (e.g. from Byk), all material were used as received. Deionized water used was supplied from filtration unit in the laboratory.
Preparation of Poly (Vinyl Alcohol) Solution
[0052] A 10% aqueous solution of PVOH polymer was prepared and kept in a sealed volumetric flask. The solution viscosity was high due to large molecular weight (MW) of polymer; hence, the aqueous solution was further diluted to 7.4% by mass to be suitable for use with foam synthesis.
[0053] In alternative examples, it is envisaged that other polymers such as, but not limited to, polyethyleneoxide, sulfonated polystyrene, polyacrylic acid, or polyacrylamide could be used
Preparation of Molybdenum Sulfide Foam Material (as a Monolith)
[0054] The foam material was initially prepared by mixing around 10 g MoS 2 powder with around 0.15 g ATTM powder in approx. 50 g of deionized water and kept for sonication for 1 hour. The PVOH polymer solution (100 g) was added to the MoS 2 /ATTM mixture and left for stirring on an IKA plate magnetic plate at a speed of 6-8 for 1 day. 3 g of the laponite clay was added to the mixture solution, kept stirring for 10 min and then the solution was transferred to petri dishes allowing the solution to dry in a fume hood for several days.
Calcination of Dry Molybdenum Sulfide Mixture in a Nitrogen Gas Environment
[0055] The dry film was thermally treated in a tube furnace in a nitrogen gas environment to decompose the ATTM, remove any residual water and decomposing partially the PVOH polymer solution to create pores. Starting from room temperature, the tube with molybdenum sulfide samples inside was firstly heated at a low rate of 4 C. degrees per min to temperatures between 20-80° C. followed by constant heating at 80° C. for 20 min. this first heating step was aimed to remove any contaminations and assure controlled environment of nitrogen inside tube. The sample was further heated at a higher rate of 10 C. degree per min to a set point of 950° C. ranging from 100-950° C. followed by constant heating at 950° C. for 30 min.
Use of the Molybdenum Sulfide Foam
[0056] The affinity of the MoS 2 porous foam was estimated from the liquid adsorption of an organosulfur compound dibenzothiophene (DBT) in an organic solvent (Toluene). Two standard solutions were made with different concentrations of DBT in toluene. The selected method includes thermodynamic equilibrium, which occurs during the immersion of the foam in the DBT solution. Additionally, kinetic takes place when testing the samples in different DBT concentrations, which induce a mass transfer driving force due to concentration difference.
[0057] The chemicals used in this procedure were toluene purines ≧99.5% GC (Sigma—from Aldrich) and dibenzothiophene 98% (from Sigma-Aldrich) as received to prepare the standard solutions.
Preparation of DBT Standard Solutions
[0058] Two standard solutions of DBT in toluene were made at the following concentrations: 100 and 1000 ppm labeled as (solution 1) and (solution 2). The appropriate solid amount of DBT was measured accurately using a balance and added to a volumetric flask and filled until the mark with toluene.
Adsorption Experiment
[0059] Immersion of approximately 10 mg of hybrid MoS foam into 3 mL of each solution in capped small vials. The vials were sonicated for 80 min at a power of 100 in a water bath to enhance the adsorption of DBT on the surface of molybdenum sulfide foam. The vials kept stable on the fume hood for static immersion in the solution for a period of 3 days. An aliquot was taken from each sample and further diluted with toluene for GC runs. The vials with solution 2 were diluted to 500 ppm, while the solution 2 vials were diluted to 10 ppm. The new solutions made from immersion aliquots were ran on the GC to measure its concentration.
[0060] Based on the standard calibration measurement of some standard DBT solution with known concentrations, the unknown samples concentrations were estimated from a calibration curve
[0061] Further uses of the molybdenum disulfide include a use as a lubricant, to produce hydrogen and as an electro-catalyst, for example in lithium batteries.
[0062] Furthermore, the molybdenum disulfide has been used in hybrid material with reduced graphene oxide. A hybrid material of silicon nanowires and molybdenum trisulfide shows a good performance in photo-electro-chemical production of hydrogen gas. Flexible transistors can be used made of molybdenum sulfide.
[0063] Other uses include thermal and acoustic insulation and filtration.
[0064] 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 was 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 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. The entirety of each of the aforementioned documents is incorporated by reference herein.
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A method for the synthesis of molybdenum disulphide foam wherein the porosity of the foam can be controlled. The porosity of the foam is employed to adapt the foam to various processes and specific requirements. The foam molybdenum disulphide structures have internal cavities are interconnected to create a large processing surface area
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation application of U.S. patent application Ser. No. 13/780,882 filed Feb. 28, 2013, which claims the benefit of Provisional Patent Application Ser. No. 61/675,725, titled “Systems and Methods for Enhancing Cognition” filed on Jul. 25, 2012, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Cognition is a group of mental processes that includes attention, memory, producing and understanding language, problem solving, and decision making. Memory is the process by which information is encoded, stored and retrieved. Working memory is the ability to mentally operate on immediately available information while persisting this information for later potential encoding into long term memory. A considerable body of neuroscience research relates working memory capacity to other cognitive abilities such as fluid intelligence. Individuals with strong working memory capacities are more likely to succeed in education and professional environments. Enhancing this capacity is highly desirable.
[0003] There have been a number of attempts to develop programs to enhance working memory capacity. For example, Cogmed Inc. has developed several variants of working memory training aimed at enhancing cognition in children with a particular focus on reducing the burden of attention deficit hyperactivity disorder (ADHD). Jaeggi and colleagues have shown that training on a challenging working memory task—called the dual n-back—improves users' performance on measures of fluid intelligence. See, Jaeggi, S. M., Buschkuehl, M., Jonides, J., & Perrig, W. J. (2008). Improving fluid intelligence with training on working memory. Proceedings of the National Academy of Sciences of the United States of America, 105(19), 6829-6833. doi:10.1073/pnas.0801268105. These promising approaches demonstrate the appeal of working memory training; however, these approaches have limitations. In particular, most of these tasks do not require substantial mental manipulation of the to-be-remembered items. This can lead to reliance on domain-specific short term working memory systems, as opposed to the domain-general executive working memory systems. The operations of domain-general memory systems are associated with transfer of training to fluid intelligence and broadly to other kinds of tasks that require working memory and control of attention. See, Kane, M., & Engle, R. (2002). The role of prefrontal cortex in working-memory capacity, executive attention, and general fluid intelligence: An individual-differences perspective. Psychonomic Bulletin & Review, 9(4), 637-671. doi:10.3758/BF03196323. Exercising these systems in a targeted fashion requires mental manipulation of the items in memory, not just maintenance.
[0004] Researchers have used complex working memory tasks to measure and train the domain-general memory capacity. See, Daneman, M., & Carpenter, P. A. (1980). Individual differences in working memory and reading. Journal of Verbal Learning and Verbal Behavior, 19(4), 450-466. doi:10.1016/S0022-5371(80)90312-6; and Turner, M. L., & Engle, R. W. (1989). Is working memory capacity task dependent? Journal of Memory and Language, 28(2), 127-154. doi:10.1016/0749-596X(89)90040-5. However, these tasks typically involve separate items for retrieval and processing (e.g., solve a math problem while remembering an unrelated number or remembering the locations of objects in the order of the numbers printed on them). These designs lack ecological validity, in that most real world tasks involving memory and control of attention involve operating on the same items that are to be remembered. For example, when an individual is making a decision about the best way to travel from point A to point B, they must pull information into working memory such as the various possible routes, the impact of traffic, public transit delays, and if the routes are walkable and operate on those representations to decide on the optimal approach. Organic uses of complex working memory like this activate prefrontal cortex in a robust and ecologically relevant manner. These uses also have the advantage of being relatively easy tasks to understand, unlike the unnatural operations in most complex working memory tasks.
[0005] What is needed are cognitive training exercises that train working memory systems in an intuitive, engaging, and adaptively challenging way to enhance cognition.
SUMMARY OF THE INVENTION
[0006] Disclosed are cognitive training exercises that are adapted to train working memory systems in humans in an intuitive, engaging, and adaptively challenging way to enhance cognition. Exercises engage users in the task of first seeing a grid with angled “bumpers” placed in various places throughout the grid. After a short initial presentation, the bumpers disappear, and the user must remember the location and orientation of the bumpers and calculate a route that a “pinball” will travel after being released from a designated starting position. In this way, the user is manipulating the remembered grid layout in working memory to solve a physically realistic task.
[0007] In one aspect of the disclosure, methods for enhancing cognition of a participant are disclosed. A method for enhancing cognition in a participant, utilizing a computing device to present visual stimuli for training, and to record responses from the participant, the method comprising: providing multiple graphical elements in a board configuration, wherein the multiple graphical elements are available for visual presentation to the participant; visually presenting a temporal sequence of a plurality of the graphical elements, including displaying each graphical element at a respective location in a visual field, wherein the plurality of graphical elements includes two or more of each of one or more circular elements (e.g. pinballs), one or more linear elements (e.g., bumpers), and one or more decoy linear elements (e.g., decoy bumpers); requiring the participant to respond to the presented sequence, including indicating a travel path for the one or more circular elements from a start point to an end point which travel path involves the circular elements engaging the linear elements and not engaging the decoy linear elements; determining whether the participant responded correctly; modifying at least one of a duration of the visually presenting or complexity of the visually presenting (number of graphical elements) based on the determining; and repeating the visually presenting, the requiring, the determining and the modifying one or more times in an iterative manner to improve the cognition of the participant. Methods can also include displaying one or more of the graphical elements for a specified duration, then ceasing to display one or more of the graphical elements. Additionally, the board configuration can be in the form of a grid, and the size of the grid can be increased or decreased to provide an additional mechanism for increasing or decreasing the complexity of the program.
[0008] Another aspect of the disclosure provides a computer-readable memory medium that stores program instructions for enhancing cognition in a participant, utilizing a computing device to present visual stimuli for training, and to record responses from the participant, wherein the program instructions are executable by a processor. The readable memory is configurable to provide multiple graphical elements in a board configuration, wherein the multiple graphical elements are available for visual presentation to the participant; visually present a temporal sequence of a plurality of the graphical elements, including displaying each graphical element at a respective location in a visual field, wherein the plurality of graphical elements includes two or more of each of one or more circular elements (e.g. pinballs), one or more linear elements (e.g., bumpers), and one or more decoy linear elements (e.g., decoy bumpers); require the participant to respond to the presented sequence, including indicating a travel path for the one or more circular elements from a start point to an end point which travel path involves the circular elements engaging the linear elements and not engaging the decoy linear elements; determine whether the participant responded correctly; modify at least one of a duration of the visually presenting or complexity of the visually presenting (number of graphical elements) based on the determining; and repeat the visually presenting, the requiring, the determining and the modifying one or more times in an iterative manner to improve the cognition of the participant. Graphical elements can also be displayed for a specified duration, then ceasing to display one or more of the graphical elements. Additionally, the board configuration can be in the form of a grid, and the size of the grid can be increased or decreased to provide an additional mechanism for increasing or decreasing the complexity of the program.
INCORPORATION BY REFERENCE
[0009] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features of the disclosure are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the disclosure are utilized, and the accompanying drawings of which:
[0011] FIG. 1A is a block diagram showing a representative example of a logic device through which use of physically intuitive complex working memory tasks improve cognition in accordance with the disclosure;
[0012] FIG. 1B is a block diagram of an exemplary computing environment through which use of physically intuitive complex working memory tasks improve cognition in accordance with the disclosure;
[0013] FIG. 1C is an illustrative architectural diagram showing some structure that can be employed by devices through which use of physically intuitive complex working memory tasks improve cognition in accordance with the disclosure;
[0014] FIG. 2 is a block diagram showing the cooperation of exemplary components of a system suitable for use in a system in which use of physically intuitive complex working memory tasks improve cognition in accordance with the disclosure;
[0015] FIG. 3A depicts a screen shot of a portion of a tutorial explaining a main task for a game in accordance with the disclosure;
[0016] FIG. 3B depicts a screen shot of a portion of a tutorial prompting a user to select an endpoint and providing a description of the way in which a pinball bounces off a bumper in accordance with the disclosure;
[0017] FIG. 4 depicts a screen shot indicating completion of the tutorial, including a prompt to begin a game in accordance with the disclosure;
[0018] FIG. 5 depicts a screen shot alerting a user that the level of game play has been decreased in accordance with the disclosure;
[0019] FIG. 6 depicts a screen shot alerting the user that an increase in difficulty will be added to the game in accordance with the disclosure;
[0020] FIG. 7 depicts a screen shot alerting the user that bumpers will be hidden in order to exercise the user's working memory in accordance with the disclosure;
[0021] FIG. 8 depicts a screen shot illustrating a decoy bumper placed in the board configuration which does not interfere with the route of the pinball in accordance with the disclosure;
[0022] FIG. 9 depicts a screen shot illustrating an example of a complex, dynamic board configuration containing an exemplar 5×5 grid and 3 decoy bumpers in accordance with the disclosure;
[0023] FIG. 10 depicts a screen shot with a final result containing a user score and highest level achieved in accordance with the disclosure;
[0024] FIG. 11 depicts a flow chart of steps performed by a computing device in accordance with the disclosure; and
[0025] FIG. 12 depicts another flow chart of steps performed by a computing device in accordance with the disclosure.
DETAILED DESCRIPTION OF THE INVENTION
I. Computing Systems
[0026] The systems and methods described herein rely on a variety of computer systems, networks and/or digital devices, including mobile devices, for operation. In order to fully appreciate how the system operates an understanding of suitable computing systems is useful. The systems and methods disclosed herein are enabled as a result of application via a suitable computing system.
[0027] FIG. 1A is a block diagram showing a representative example logic device through which a browser can be accessed to implement the present invention. A computer system (or digital device) 100 , which may be understood as a logic apparatus capable of reading instructions from media 114 and/or network port 106 , is connectable to a server 110 , and has a fixed media 116 . The computer system 100 can also be connected to the Internet or an intranet. The system includes central processing unit (CPU) 102 , disk drives 104 , optional input devices, illustrated as keyboard 118 and/or mouse 120 and optional monitor 108 . Data communication can be achieved through, for example, communication medium 109 to a server 110 at a local or a remote location. The communication medium 109 can include any suitable means of transmitting and/or receiving data. For example, the communication medium can be a network connection, a wireless connection or an internet connection. It is envisioned that data relating to the present disclosure can be transmitted over such networks or connections. The computer system can be capable of, or in at least some situations capable of, communicating with a participant and/or a device used by a participant. The computer system is capable of communicating with other computers over the Internet, or with computers via a server.
[0028] FIG. 1B depicts another exemplary computing system 100 . The computing system 100 is capable of, or in at least some situations adaptable for, executing a variety of computing applications 138 , including computing applications, a computing applet, a computing program, or other instructions for operating on computing system 100 to perform at least one function, operation, and/or procedure. Computing system 100 is controllable by computer readable storage media for tangibly storing computer readable instructions, which may be in the form of software. The computer readable storage media capable of, or in at least some situations adaptable to, tangibly store computer readable instructions can contain instructions for computing system 100 for storing and accessing the computer readable storage media to read the instructions stored thereon themselves. Such software may be executed within CPU 102 to cause the computing system 100 to perform desired functions. In many known computer servers, workstations and personal computers CPU 102 is implemented by micro-electronic chips CPUs called microprocessors. Optionally, a co-processor, distinct from the main CPU 102 , can be provided that performs additional functions or assists the CPU 102 . The CPU 102 may be connected to co-processor through an interconnect. One common type of coprocessor is the floating-point coprocessor, also called a numeric or math coprocessor, which is designed to perform numeric calculations faster and better than the general-purpose CPU 102 .
[0029] As will be appreciated by those skilled in the art, a computer readable medium stores computer data, which data can include computer program code that is executable by a computer, in machine readable form. By way of example, and not limitation, a computer readable medium may comprise computer readable storage media, for tangible or fixed storage of data, or communication media for transient interpretation of code-containing signals. Computer readable storage media, as used herein, refers to physical or tangible storage (as opposed to signals) and includes without limitation volatile and non-volatile, removable and non-removable storage media implemented in any method or technology for the tangible storage of information such as computer-readable instructions, data structures, program modules or other data. Computer readable storage media includes, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other solid state memory technology, CD-ROM, DVD, or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other physical or material medium which can be used to tangibly store the desired information or data or instructions and which can be accessed by a computer or processor.
[0030] In operation, the CPU 102 fetches, decodes, and executes instructions, and transfers information to and from other resources via the computer's main data-transfer path, system bus 140 . Such a system bus connects the components in the computing system 100 and defines the medium for data exchange. Memory devices coupled to the system bus 140 include random access memory (RAM) 124 and read only memory (ROM) 126 . Such memories include circuitry that allows information to be stored and retrieved. The ROMs 126 generally contain stored data that cannot be modified. Data stored in the RAM 124 can be read or changed by CPU 102 or other hardware devices. Access to the RAM 124 and/or ROM 126 may be controlled by memory controller 122 . The memory controller 122 may provide an address translation function that translates virtual addresses into physical addresses as instructions are executed.
[0031] In addition, the computing system 100 can contain peripherals controller 128 responsible for communicating instructions from the CPU 102 to peripherals, such as, printer 142 , keyboard 118 , mouse 120 , and data storage drive 143 . Display 108 , which is controlled by a display controller 163 , is used to display visual output generated by the computing system 100 . Such visual output may include text, graphics, animated graphics, and video. The display controller 134 includes electronic components required to generate a video signal that is sent to display 108 . Further, the computing system 100 can contain network adaptor 136 which may be used to connect the computing system 100 to an external communications network 132 .
II. Networks and Internet Protocol
[0032] As is well understood by those skilled in the art, the Internet is a worldwide network of computer networks. Today, the Internet is a public and self-sustaining network that is available to many millions of users. The Internet uses a set of communication protocols called TCP/IP (i.e., Transmission Control Protocol/Internet Protocol) to connect hosts. The Internet has a communications infrastructure known as the Internet backbone. Access to the Internet backbone is largely controlled by Internet Service Providers (ISPs) that resell access to corporations and individuals.
[0033] The Internet Protocol (IP) enables data to be sent from one device (e.g., a phone, a Personal Digital Assistant (PDA), a computer, etc.) to another device on a network. There are a variety of versions of IP today, including, e.g., IPv4, IPv6, etc. Other IPs are no doubt available and will continue to become available in the future, any of which can be used without departing from the scope of the invention. Each host device on the network has at least one IP address that is its own unique identifier and acts as a connectionless protocol. The connection between end points during a communication is not continuous. When a user sends or receives data or messages, the data or messages are divided into components known as packets. Every packet is treated as an independent unit of data and routed to its final destination—but not necessarily via the same path.
III. Wireless Networks
[0034] Wireless networks can incorporate a variety of types of mobile devices, such as, e.g., cellular and wireless telephones, PCs (personal computers), laptop computers, wearable computers, cordless phones, pagers, headsets, printers, PDAs, etc. For example, mobile devices may include digital systems to secure fast wireless transmissions of voice and/or data. Typical mobile devices include some or all of the following components: a transceiver (for example a transmitter and a receiver, including a single chip transceiver with an integrated transmitter, receiver and, if desired, other functions); an antenna; a processor; display; one or more audio transducers (for example, a speaker or a microphone as in devices for audio communications); electromagnetic data storage (such as ROM, RAM, digital data storage, etc., such as in devices where data processing is provided); memory; flash memory; and/or a full chip set or integrated circuit; interfaces (such as universal serial bus (USB), coder-decoder (CODEC), universal asynchronous receiver-transmitter (UART), phase-change memory (PCM), etc.). Other components can be provided without departing from the scope of the invention.
[0035] Wireless LANs (WLANs) in which a mobile user can connect to a local area network (LAN) through a wireless connection may be employed for wireless communications. Wireless communications can include communications that propagate via electromagnetic waves, such as light, infrared, radio, and microwave. There are a variety of WLAN standards that currently exist, such as Bluetooth®, IEEE 802.11, and the obsolete HomeRF.
[0036] By way of example, Bluetooth products may be used to provide links between mobile computers, mobile phones, portable handheld devices, personal digital assistants (PDAs), and other mobile devices and connectivity to the Internet. Bluetooth is a computing and telecommunications industry specification that details how mobile devices can easily interconnect with each other and with non-mobile devices using a short-range wireless connection. Bluetooth creates a digital wireless protocol to address end-user problems arising from the proliferation of various mobile devices that need to keep data synchronized and consistent from one device to another, thereby allowing equipment from different vendors to work seamlessly together.
[0037] An IEEE standard, IEEE 802.11, specifies technologies for wireless LANs and devices. Using 802.11, wireless networking may be accomplished with each single base station supporting several devices. In some examples, devices may come pre-equipped with wireless hardware or a user may install a separate piece of hardware, such as a card, that may include an antenna. By way of example, devices used in 802.11 typically include three notable elements, whether or not the device is an access point (AP), a mobile station (STA), a bridge, a personal computing memory card International Association (PCMCIA) card (or PC card) or another device: a radio transceiver; an antenna; and a MAC (Media Access Control) layer that controls packet flow between points in a network.
[0038] In addition, Multiple Interface Devices (MIDs) may be utilized in some wireless networks. MIDs may contain two independent network interfaces, such as a Bluetooth interface and an 802.11 interface, thus allowing the MID to participate on two separate networks as well as to interface with Bluetooth devices. The MID may have an IP address and a common IP (network) name associated with the IP address.
[0039] Wireless network devices may include, but are not limited to Bluetooth devices, WiMAX (Worldwide Interoperability for Microwave Access), Multiple Interface Devices (MIDs), 802.11x devices (IEEE 802.11 devices including, 802.11a, 802.11b and 802.11g devices), HomeRF (Home Radio Frequency) devices, Wi-Fi (Wireless Fidelity) devices, GPRS (General Packet Radio Service) devices, 3 G cellular devices, 2.5 G cellular devices, GSM (Global System for Mobile Communications) devices, EDGE (Enhanced Data for GSM Evolution) devices, TDMA type (Time Division Multiple Access) devices, or CDMA type (Code Division Multiple Access) devices, including CDMA2000. Each network device may contain addresses of varying types including but not limited to an IP address, a Bluetooth Device Address, a Bluetooth Common Name, a Bluetooth IP address, a Bluetooth IP Common Name, an 802.11 IP Address, an 802.11 IP common Name, or an IEEE MAC address.
[0040] Wireless networks can also involve methods and protocols found in, Mobile IP (Internet Protocol) systems, in PCS systems, and in other mobile network systems. With respect to Mobile IP, this involves a standard communications protocol created by the Internet Engineering Task Force (IETF). With Mobile IP, mobile device users can move across networks while maintaining their IP Address assigned once. See Request for Comments (RFC) 3344. NB: RFCs are formal documents of the Internet Engineering Task Force (IETF). Mobile IP enhances Internet Protocol (IP) and adds a mechanism to forward Internet traffic to mobile devices when connecting outside their home network. Mobile IP assigns each mobile node a home address on its home network and a care-of-address (CoA) that identifies the current location of the device within a network and its subnets. When a device is moved to a different network, it receives a new care-of address. A mobility agent on the home network can associate each home address with its care-of address. The mobile node can send the home agent a binding update each time it changes its care-of address using Internet Control Message Protocol (ICMP).
[0041] FIG. 1C depicts components that can be employed in system configurations enabling the systems and technical effect of this disclosure, including wireless access points to which client devices communicate. In this regard, FIG. 1C shows a wireless network 150 connected to a wireless local area network (WLAN) 152 . The WLAN 152 includes an access point (AP) 154 and a number of user stations 156 , 156 ′. For example, the network 150 can include the Internet or a corporate data processing network. The access point 154 can be a wireless router, and the user stations 156 , 156 ′ can be portable computers, personal desk-top computers, PDAs, portable voice-over-IP telephones and/or other devices. The access point 154 has a network interface 158 linked to the network 150 , and a wireless transceiver in communication with the user stations 156 , 156 ′. For example, the wireless transceiver 160 can include an antenna 162 for radio or microwave frequency communication with the user stations 156 , 156 ′. The access point 154 also has a processor 164 , a program memory 166 , and a random access memory 168 . The user station 156 has a wireless transceiver 170 including an antenna 172 for communication with the access point station 154 . In a similar fashion, the user station 156 ′ has a wireless transceiver 170 ′ and an antenna 172 for communication to the access point 154 . By way of example, in some embodiments an authenticator could be employed within such an access point (AP) and/or a supplicant or peer could be employed within a mobile node or user station. Desktop 108 and key board 118 or input devices can also be provided with the user status.
IV. Access Via Browser
[0042] In at least some configurations, a user executes a browser to view digital content items and can connect to the front end server via a network, which is typically the Internet, but can also be any network, including but not limited to any combination of a LAN, a MAN, a WAN, a mobile, wired or wireless network, a private network, or a virtual private network. As will be understood a very large numbers (e.g., millions) of users are supported and can be in communication with the website at any time. The user may include a variety of different computing devices. Examples of user devices include, but are not limited to, personal computers, digital assistants, personal digital assistants, cellular phones, mobile phones, smart phones or laptop computers.
[0043] The browser can include any application that allows users to access web pages on the World Wide Web. Suitable applications include, but are not limited to, Microsoft Internet Explorer®, Netscape Navigator®, Mozilla® Firefox, Apple® Safari or any application capable of or adaptable to allowing access to web pages on the World Wide Web. The browser can also include a video player (e.g., Flash™ from Adobe Systems, Inc.), or any other player adapted for the video file formats used in the video hosting website. Alternatively, videos can be accessed by a standalone program separate from the browser. A user can access a video from the website by, for example, browsing a catalog of digital content, conducting searches on keywords, reviewing aggregate lists from other users or the system administrator (e.g., collections of videos forming channels), or viewing digital content associated with particular user groups (e.g., communities).
V. Computer Network Environment
[0044] Computing system 100 , described above, can be deployed as part of a computer network used to achieve the desired technical effect and transformation. In general, the above description for computing environments applies to both server computers and client computers deployed in a network environment. FIG. 2 illustrates an exemplary illustrative networked computing environment 200 , with a server in communication with client computers via a communications network 250 . As shown in FIG. 2 , server 210 may be interconnected via a communications network 250 (which may be either of, or a combination of a fixed-wire or wireless LAN, WAN, intranet, extranet, peer-to-peer network, virtual private network, the Internet, or other communications network) with a number of client computing environments such as tablet personal computer 202 , smart phone 204 , personal computer 202 , and personal digital assistant 208 . In a network environment in which the communications network 250 is the Internet, for example, server 210 can be dedicated computing environment servers operable to process and communicate data to and from client computing environments via any of a number of known protocols, such as, hypertext transfer protocol (HTTP), file transfer protocol (FTP), simple object access protocol (SOAP), or wireless application protocol (WAP). Other wireless protocols can be used without departing from the scope of the disclosure, including, for example Wireless Markup Language (WML), DoCoMo i-mode (used, for example, in Japan) and XHTML Basic. Additionally, networked computing environment 200 can utilize various data security protocols such as secured socket layer (SSL) or pretty good privacy (PGP). Each client computing environment can be equipped with operating system 238 operable to support one or more computing applications, such as a web browser (not shown), or other graphical user interface (not shown), or a mobile desktop environment (not shown) to gain access to server computing environment 200 .
[0045] In operation, a user (not shown) may interact with a computing application running on a client computing environment to obtain desired data and/or computing applications. The data and/or computing applications may be stored on server computing environment 200 and communicated to cooperating users through client computing environments over exemplary communications network 250 . The computing applications, described in more detail below, are used to achieve the desired technical effect and transformation set forth. A participating user may request access to specific data and applications housed in whole or in part on server computing environment 200 . These data may be communicated between client computing environments and server computing environments for processing and storage. Server computing environment 200 may host computing applications, processes and applets for the generation, authentication, encryption, and communication data and applications and may cooperate with other server computing environments (not shown), third party service providers (not shown), network attached storage (NAS) and storage area networks (SAN) to realize application/data transactions.
VII. Software Programs Implementable in the Computing and Network Environments to Achieve a Desired Technical Effect or Transformation
[0046] FIG. 3A depicts a screen shot 300 of a board 302 and a portion of a tutorial explaining a main task for a game. An instruction 310 is provided on the screen, for example “Select the end point to launch the ball.” A start point 312 appears in a first location on the board 302 , and an end point 314 is in a second location different from the first on the board 302 . As depicted in this screen shot, for example, the start point 312 is on the left side of the screen and the end point 314 is on the right side of the screen.
[0047] FIG. 3B depicts a screen shot 300 of a portion of a tutorial prompting a user to select an endpoint and providing a description of the way in which a pinball 316 bounces off a graphical element having at least one linear face such as a bumper 318 . Thus, for example, the start point 312 is depicted on the left side of the board 302 , with a bumper 318 on the right side of the board 302 directly across from the start point. The bumper 318 is depicted as a linear segment having a length sufficient to engage a surface of the pinball 316 such that the pinball 316 will strike the bumper and be deflected in a new direction. In this depiction, the bumper 318 is positioned horizontally across from the start point 312 and is angled at 45° angle from the horizontal such that when the pinball 316 hits the surface of the bumper 318 it travels in a direction perpendicular to it's first direction of travel (90° from horizontal).
[0048] FIG. 4 depicts a screen shot 400 indicating completion of the tutorial, including a prompt 410 to begin a game. FIG. 5 depicts a screen shot 500 with an instruction 510 alerting a user that the level of game play has been decreased. FIG. 6 depicts a screen shot 600 with an instruction 610 alerting the user that an increase in difficulty will be added to the game. FIG. 7 depicts a screen shot 700 with an instruction 710 alerting the user that bumpers will be hidden in order to exercise the user's working memory.
[0049] FIG. 8 depicts a screen shot 800 illustrating a bumper 818 and a decoy bumper 818 ′ placed in the board 802 configuration which does not interfere with the route 804 of the pinball 816 .
[0050] FIG. 9 depicts a screen shot illustrating an example of a complex, dynamic board 902 configuration containing an exemplar 5×5 grid and 3 decoy bumpers.
[0051] FIG. 10 depicts a screen shot 1000 with a final result containing a user score and highest level achieved.
[0052] The object of this exercise is for a user to successfully get the pinball from the starting point to the ending point by bouncing the pinball off the bumpers positioned on the board. Initially, all bumpers are presented on the board such that the bumpers are visible to the user for a brief period of time. Then, in most levels, the bumpers disappear and are no longer visible by the user. After the bumpers disappear, the user is shown the ball's starting point and must determine, based on the positioning of the now-invisible bumpers, where the ball will end up. This requires the user to recall the position that the bumpers had occupied. The ball always travels outward perpendicularly from the wall where it is launched until it hits a bumper. The ball ricochets off the bumpers according to the rule, “the angle of incidence equals the angle of deflection.” In a current implementation, all bumpers are angled at 45 degrees, but, as will be appreciated by those skilled in the art, this could be altered in other implementations. For example, all bumpers could be positioned at an angle other than 45 degrees, or bumpers could be positioned at a plurality of angles.
[0053] If the correct end point is selected, the user is rewarded for a correct trial. If the incorrect point is chosen, the user receives the incorrect trial feedback, and is shown the correct path. This exercise requires the user to recall the location and orientation of all the bumpers, while calculating a route through grid. This exercises working memory systems in a domain general way, in a form that is physically intuitive and engaging.
[0054] The user is introduced to the training exercise via a short interactive tutorial describing the gameplay elements, ( FIGS. 3A-B ). The tutorial prompts the user to complete a series of simple game configurations with guided messages and prompts. Gameplay features such as the angle at which the pinball bounces off of each bumper are explained with animations and helpful text, ( FIG. 3B ). Once the tutorial is completed, the user is prompted to play the game at the first level, ( FIG. 4 ).
[0055] The main gameplay flow is based on varying levels of difficulty. As the user progresses up through each level, the difficulty is increased. If two incorrect answers are selected in a row, the user is moved down a level and the difficulty is decreased, ( FIG. 5 ). Once two correct answers are selected in a row, the user is moved up a level and the difficulty is increased until a total of 15 trials are completed—this is the current best mode, but other game lengths (i.e., number of trials) and methods of moving up and down in difficulty (e.g., one correct or incorrect to change level, or a Bayesian adaptive algorithm predicting the optimal level) could be used as well.
[0056] On subsequent plays of the game, the user starts just below their previous level. This allows the user to regain familiarity with the training task and helps build confidence. In some configurations, the user starts at a subsequent start level that can be based on, for example, the previous level as well as the length of time that has passed since a user has last played.
[0057] Difficulty is controllable by adjusting one or more of the following variables:
Board size
An initial level starts at a 3×3 grid and grows to, for example, 6×6
Number of bumpers on the board, ( FIG. 6 ) Visibility of bumpers or decoy bumpers
At later levels, bumpers and/or decoy bumpers are shown and then hidden, ( FIG. 7 ) The amount of time the bumpers or decoy bumpers are visible The number of bumpers and/or decoy bumpers that are visible (e.g., a subset of bumpers and/or decoy bumpers can be made invisible)
Number of decoy bumpers
In order to mitigate memorization of board configurations, decoy bumpers are added which are never activated during the trial, ( FIG. 8 )
Size (e.g., length) of bumpers and/or decoy bumpers Shape of bumpers and/or decoy bumpers Angle of bumpers and/or decoy bumpers
All bumpers and/or decoy bumpers angled at a single angle (e.g., 45 degrees) Bumpers and/or decoy bumpers angled as a plurality of angles
[0072] The core gameplay mechanic is the selection of the final position for the pinball based on a starting location and a series of bumpers that make up a board configuration. This configuration is determined by the current level of difficulty and has been designed to provide a smooth transition between levels.
[0073] As will be appreciated by those skilled in the art, implementation can also vary depending on the platform for delivery. For example, the grid configuration may be adapted to the screen size of the electronic device and the nature of the input mode. Thus, in one configuration a grid of 3×3 which uses a mouse click as input could be the configuration in a computer while a grid of 5×7 which relies on a touch screen interface for input might be used for a mobile device or tablet.
[0074] The process of generating a dynamic board configuration begins with the selection of the target board size and the number of bumpers and decoys from within a range based on the difficulty of the current level. In the current best mode implementation, these ranges have been hardcoded into the game based on user testing and are updated periodically from data gathered across a large user-base of active players (T ABLE 1).
[0075] Once the board size, number of bumpers, and number of decoys have been determined, bumpers are randomly placed on the board to generate a route to an end location. These bumpers are then oriented in such a way as to create a valid surface on which the pinball will bounce and continue along the generated path. Once the route is determined, decoy bumpers are placed on grid elements that do not lie along the route. If the randomly chosen route does not allow for the placement of the selected number of decoy bumpers, a new route is generated until a valid route is found. In this way a complete board configuration is generated. Since routes are dynamically determined, there are a vast number of possible routes and therefore unique trials ( FIG. 9 ).
[0076] After a predetermined number of trials (e.g., fifteen trials), the user's game is completed and they are shown a results screen on which their score is displayed alongside the highest level of difficulty achieved ( FIG. 10 ).
[0000]
TABLE 1
Level
Board Size
Number of Bumpers
Decoy Range
1
3 × 3
1
0-0
2
3 × 3
2
0-1
3
3 × 3
1
0-0
4
3 × 3
2
0-1
5
4 × 4
3
1-2
6
4 × 4
4
1-3
7
5 × 5
4
1-2
8
5 × 5
5
2-3
9
5 × 5
6
3-4
10
5 × 5
7
4-5
11
5 × 5
7
3-4
12
5 × 5
8
3-6
13
6 × 6
8
2-5
14
6 × 6
9
3-5
15
6 × 6
9
2-5
16
6 × 6
10
3-6
17
6 × 6
11
4-7
18
6 × 6
12
4-8
19
6 × 6
13
5-8
20
6 × 6
14
5-9
21
6 × 6
15
6-9
22
6 × 6
16
6-10
[0077] FIG. 11 is a flowchart illustrating an embodiment of steps performed by a computing device to enhance cognition of a participant. The computing device provides for display multiple graphical elements in a board configuration (Step 1105 ). A temporal sequence of graphical elements is displayed (Step 1110 ), where the graphical elements include circular elements (e.g., pinballs), linear elements (e.g., bumpers), and/or decoy linear elements (e.g., decoy bumpers). The participant responds to the presented sequence and the computing device receives the response (Step 1115 ). The response includes an indication of a travel path for the one or more circular elements from a start point to an end point which travel path involves the circular elements engaging the linear elements and not engaging the decoy linear elements. The computing device then determines if the response is correct (Step 1120 ). If the response is incorrect, in one embodiment the complexity and/or the duration of the sequence is decreased (Step 1125 ). If the response is correct, in one embodiment the complexity and/or the duration of the sequence is increased (Step 1130 ). Steps 1110 - 1130 can then be repeated in an iterative manner to improve the cognition of the participant. In one embodiment, the board is a grid. The size of the grid can be adjusted to adjust complexity.
[0078] FIG. 12 is another flowchart illustrating an embodiment of steps performed by a computing device to enhance cognition of a participant or user of a client device. A computing device transmits, to the client device for display for a predetermined amount of time, a grid with bumpers placed in different positions throughout the grid (Step 1205 ). The computing device determines if the predetermined amount of time has elapsed (Step 1210 ). If not, the grid with bumpers continues to be displayed (Step 1215 ). If so, the computing device causes the client device to display the grid without the bumpers (Step 1220 ). The computing device then receives, from the user, a route that a circular element will travel after being released from a designated starting position (Step 1225 ). The computing device determines if the received route is correct (Step 1230 ). In one embodiment, the complexity of the grid and/or the duration of the display of the grid with bumpers is adjusted based on if the route is correct (Steps 1235 or 1240 ). In one embodiment, the complexity is adjusted by adjusting the size of the grid.
[0079] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.
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The disclosure is directed to cognitive training exercise adapted to train working memory systems in mammals in an intuitive, engaging, and adaptively challenging way to enhance cognition. Exercises engage users in the task of first seeing a grid with angled “bumpers” placed in various places throughout the grid. After a short initial presentation, the bumpers disappear, and the user must remember the location and orientation of the bumpers and calculate a route that a “pinball” will travel after being released from a designated starting position. In this way, the user is manipulating the remembered grid layout in working memory to solve a physically realistic task.
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This is a continuation of application Ser. No. 635,931, filed Nov. 28, 1975, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vibration eliminating devices providing three point suspension employing a combination of fluid assemblies for self-centering the load being supported.
2. Brief Description of the Prior Art
In the past, it has been the conventional practice to support loads on fixed structure by means of resilient pads such as compressed rubber, cork, rubberized diaphragms or the like. Usually, these latter elements are captured in a frame which is then secured between the load and the supporting structure so that the device will flex or decrease vibration and shock when applied loads are transmitted to the cargo or product being supported. Furthermore, it has been current practice to combine several of such devices so that multiple point suspension is derived. However, it is the usual practice to employ four or two point suspension but it is not the general case to use an odd number of suspension points. Furthermore, although the prior art elements are flexible and composed of shock absorbing materials, they only partially reduce the amount of vibration and it is sometimes difficult to adjust or pressurize the elements to a desired degree of softness to completely eliminate vibration. Examples of the prior art shock absorbing systems are disclosed in U.S. Pat. Nos. 3,476,340; 3,545,706 and 2,232,456. Although these prior mounting systems are operable for their intended purposes, it is to be noted that the prior art references show angular suspensions for the load being carried but that four or two point suspensions are employed only for securing the opposite ends of the load. Also, it is to be noted that the shock absorbing elements are relatively rigid and do not employ adjustment means for determining their degree of compressive loading. Furthermore, the prior art devices employ vibration suppressing mounts which are at angles other than perpendicular to the horizontal and which do not provide for a three point suspension system.
Therefore, a long standing need has existed to provide for a more efficient vibration eliminating suppression system than the prior art devices can offer. Such a need also encompasses such a requirement for self-centering the load on the shock mounting system without restraints so that installation is simplified as well as suspension efficiency increased.
SUMMARY OF THE INVENTION
Accordingly, the above problems and difficulties are obviated by the present invention which provides a novel system having a one to three point suspension mount which is self-centering. The invention includes the placement of at least one to three fluid means such as pneumatic assemblies which are arranged to achieve vibration supression.
In one form of the invention, each of the fluid means includes an inflatable member or element disposed between opposing parallel surfaces carried by brackets which are respectively secured to the cargo or load and the supporting structure. Preferably, the inflatable member or element is carried within the circular side wall of a dish or pan-like member which is fixedly secured to a selected one of the brackets.
In the case of an internal combustion engine-powered generator used as a power supply for boats, motor-homes, and aircraft or the like, the generator may be mounted per this invention and using air (4 lbs PSI) encased in a light innertube, the vibrating power unit still vibrates at the normal amplitude; but this vibration will not pass through the supporting means (4 lbs PSI of air restrained by a light air bag) and into the parent vehicle.
Therefore, it is among the primary objects of the present invention to provide a novel vibration eliminating system.
Another object of the present invention is to provide a novel pneumatic means for vibration absorption encountered by cargo during transit in which the fluid viscosity is adjusted to determine its compressibility characteristics for efficiently reacting to applied vibration.
Still another object of the present invention is to provide a novel vibration suppression system employing inflatable tubes accommodating transmission of loads into the supporting structure.
Yet a further object of the present invention is to provide a novel self-centering, three point suspension system for mounting cargo employing one or more tubes that may be filled with fluids of different viscosities and/or pressures in order to support cargo weight.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of a typical cargo or load suspended on the three point suspension and vibration absorbing system of the present invention;
FIG. 2 is a top plan view of the suspension system and cargo as shown in FIG. 1;
FIG. 3 is an enlarged cross sectional view of one element in the three point suspension system as taken in the direction of arrow 3--3 of FIG. 2;
FIG. 4 is a sectional view taken in the direction of arrow 4--4 of FIG. 3;
FIG. 5 is a side elevational view illustrating another embodiment of the present invention employing a pair of pneumatic elements;
FIG. 6 is a transverse cross sectional view of another form of the inventive concept employing self-centering characteristics; and
FIG. 7 is a view similar to that shown in FIG. 6 illustrating the system under applied load.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the novel vibration suppression and absorbing suspension system is illustrated in connection with mounting a cargo or load 10 onto a supporting base or frame or platform 11. The suspension system includes a combination of three suspension assemblies which are arranged at approximately 120° apart and which are mounted in an angularly orientation with respect to the supporting floor 11. Each of the suspension assemblies comprising the three point system is identified by the numerals 12, 13 and 14. It can be seen that the suspension assemblies are arranged on different sides and end of the cargo 10.
Referring in detail to FIG. 2, it can be seen that the suspension assemblies 12-14 inclusive are arranged to provide a three point suspension system so that the load or cargo 10 is self-centering between the suspension assemblies. The angular relationship illustrated is approximately 120° as is indicated by the double arrows degree line identified as numeral 15. However, it is to be understood that other angular relationships may be established than 120° since shape and general overall configuration of the load or cargo 10 must be considered. It is critical that the angular relationship be such that horizontal angles with respect to adjacent suspension assemblies be as close to 120° as possible.
Referring now in detail to FIG. 3, an enlarged view of suspension assembly 12 is illustrated in cross section and it is to be understood that the other two suspension assemblies are constructed and assembled in an identical manner. A pair of brackets 16 and 17 are carried on the supporting frame or floor 11 and cargo 10, respectively. Each of the brackets 16 and 17 include a flat surface 18 and 19 which oppose each other and are parallel with respect to each other. Surface 18 carries a circular open pan 20 which is fixedly secured to the bracket 16 by means of a fastener 21. The pan 20 opens in the direction of opposing surface 19 of bracket 17 and the pan 20 carries a fluid means such as a pneumatic element 22 therein as confined by the circular side wall of the pan. The pneumatic element takes the form of an inflatable tube which includes a conventional one-way or check valve 23 for conducting suitable inflation gases or other fluids to the interior of the tube. As an example, air under pressure is introduced through the valve stem 23 into the interior of the tube 22. The tube 22 may be inflated to a desired or specified psi depending upon the cargo or load to be suspended.
It is also to be noted that the vertical angular orientation of the pneumatic element 22 with respect to its supporting floor is approximately 30°. By angling the three pneumatic elements at approximately 30°, self-centering of the load 10 is achieved and by employing three pneumatic elements, the three point suspension of the load or cargo is achieved. In any event, the vertical angle should be determined to provide the lowest vibration level for each particular application. The angle may even be more than 90° with respect to the supporting surface such as angled outwards. The angular relationship is influenced by the applied loads with respect to the cargo center of gravity. An alternating load applied above the CG will cause a maximum load to be experienced by the supporting structure because the system supports have a horizontal stiffness. There will also be a horizontal load and an arcuate moment above the CG if the load is applied to the cargo higher or lower than the CG. This latter load and moment may either add to or subtract from the load felt by the support structure.
However, if an alternating load is applied at the CG, there is no reaction at the support structure because of the reciprocation of the load. If the alternating load is applied above or below the CG, there will be the same kind of added load reaction at the support structure as there is with the former described system because the cargo or unit will attempt to rotate and thereby always add to the total load felt by the support structure.
To avoid or obviate rocking of the cargo, weight can be added to the top or bottom of the cargo or unit to make the CG coincide with the plane of the load.
The inventive concept is intended to include three dimensional mounting arrangements which will support a load regardless of what the attitude of the cargo or unit may be. In this instance, a fluid mounting means would be attached at multiple points with their line of action extending through the CG of the cargo or unit.
In FIG. 4, it can be seen that the pneumatic element 22 is circular and that it is coaxially disposed with respect to the pan 20 and the fastener 21 securing the pan to bracket 18. Each of the pneumatic tubes associated with each of the suspension assemblies is carried in a pie-shaped base or pan 20 which is rigidly attached to the support or bracket so that the angle orientation is maintained with respect to the support. A cargo or load 10 is carried on the opposite side of the pneumatic element and can move toward and away from the pan or pie-shaped base in a resilient manner depending upon the degree of air pressure or inflation carried in the pneumatic element.
Another suspension assembly covered by the present invention is illustrated in FIG. 5. In this latter embodiment, the cargo 10 includes a angle bracket 30 having parallel opposite sides or surfaces 31 and 32 to which are attached a pair of pneumatic elements 33 and 34, respectively. The opposite sides of the pneumatic elements are disposed within the pie-shaped bases or pans 35 and 36 and the elements are held together in compression against surfaces 31 and 32 by a common fastener 37. In this arrangement, the cargo is still mounted at three point by the cooperating shock absorbing pneumatic element. However, the dual arrangement of the pneumatic element per suspension assembly permits the top tube 33 to be less inflated than the lower pneumatic element of the pair identified by numeral 34.
For example, element 33 may be inflated to an air pressure of two pounds whereas the inflation on element 34 may be five pounds. Such an arrangement provides restraint of cargo during shock absorption as well as vibration suppression during severe operation such as in the field of marine vehicles, off the road vehicles, aircraft or the like.
In view of the foregoing, it can be seen that the suspension system of the present invention provides for a three point, self-centering suspension for the load or cargo 10 and that the vibration and/or shock loads encountered by the frame or support 11 are absorbed by the pneumatic elements and are not transmitted into the load. The pneumatic elements are adjustable by inflation or deflation of the pneumatic elements at the selection of the operator or user. Also, the tubes may be filled with a liquid rather than a gas so that vertical stiffness is gained with low horizontal stiffness. The desired tube fill, whether gas or liquid, may be selected to obtain a low or high vertical spring rate. If the tube is elastic, such as a rubber composition, and the fluid is of significant viscosity, then damping is obtained from the system. In this latter instance, the system may be considered a shock absorber.
Referring now to FIG. 6, the inventive system is shown to include a tube 40 of elastic composition which is filled with a gas or liquid fluid. The tube is compressed between a supporting surface indicated by numeral 41 and the curved surface 42 of a pan 43. The contour of surface 42 is sufficient to cause the surface to seek or re-locate the center. The larger the radius of curvature, the lower the horizontal stiffness. In FIG. 7, the pan will move to the right of the drawing under compressive loading because of asymmetrical application of pressure to the tube. The arrows show pressure distribution under load. The resultant action provides self-centering back to the symetrical loading shown in FIG. 6.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
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A vibration eliminating mount for supporting a load is disclosed herein having a three point suspension wherein each of the three points includes a pair of angularly disposed brackets secured to the load and the support respectively. Carried between opposing parallel surfaces on the brackets is a fluid vibration eliminating assembly movably separating the pair of brackets. The assembly is carried in a dish or pan which is fixedly secured to at least one of the brackets and provision is made for accommodating a fluid valve for suitably pressurizing the assembly.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for cleaning paint applicators and more particularly for cleaning roller-type paint applicators.
The use of roller applicators for applying paint is very popular as an even coating with a good finish is obtained. However, such paint rollers are difficult to clean and hence in many cases the rollers are used only a few times and then disposed of. This problem applies to both rollers used for water based paints, paints with solvent bases other than water, and other substances.
A roller after being used may be hand washed in a large excess of cleaning fluid. While this will remove surface paint on the roller pad or fabric cover, it will not efficiently remove paint or other deposits deep down in the pad at the core of the roller. Indeed, conventional means of flushing water over the fabric cover externally causes paint to be flushed deep into the cover, thereby never really cleaning the cover throughout. This deep down paint or deposit, if allowed to remain in the pad, can harden and significantly reduce the life and efficiency of the paint roller.
In addition, the roller cover core may be easily damaged by hand washing the fabric cover since many roller cores are made of paper products which are coated, but not strong enough to withstand the squeezing action during hand washing.
It is an object, therefore, of this invention to provide a cleaning device for a paint roller which will alleviate one or both of the problems mentioned above.
A paint roller cleaner device as shown in FIG. 1 of the specification currently exists in the marketplace. In addition to other differences, the present invention is designed so it can be screwed onto a faucet such that the roller is moved in a vertical motion through the cleaning device. Accordingly, the water or cleaning liquid flows evenly down and around the roller fabric cover or pad flushing the paint or other substance completely away rather than letting the paint settle at the bottom of the roller cover as is the tendency when the roller is moved in a horizontal direction through the paint roller cleaning device as with the device shown in FIG. 1 when mounted to a faucet. Additionally, the present invention includes scrubber elements about the circumference of a portion thereof. By rotating the roller with a left and right twisting motion as it is moved vertically through the cleaning device, a scrubbing action is imparted to the roller cover. This facilitates cleaning of hard to clean roller covers which often result when using a thick, sticky paint or substance or when the paint or substance has dried onto the roller cover.
Rollers are used for other applications such as glue or ink, or dampening rollers on printing presses. Cleaning of these rollers is time consuming and hence it is a further object of this invention to provide means to facilitate the cleaning of roller applicators in general.
SUMMARY OF THE INVENTION
The present invention relates to a paint roller cleaning apparatus for cleaning a roller pad of a paint roller. The paint roller cleaning apparatus includes an annular sleeve having an outer surface and an inner surface adapted to have an interference fit with the roller pad. Liquid passage means is provided within the annular sleeve intermediate of the inner and outer surfaces. Liquid entry means is interconnected to the liquid passage means, the liquid entry means including a threaded cylindrical portion adapted for threaded attachment of the cleaning apparatus to a source of water or other liquid. The threaded cylindrical portion having a substantially parallel orientation with respsect to the annular sleeve. Liquid outlet means in communication with the liquid passage means is provided on the inner surface of the annular sleeve. A plurality of spaced, axially directed scrubber elements positioned circumferentially about the inner surface of the annular sleeve along at least a portion of the longitudinal extent thereof are provided.
In one embodiment of the present invention, the liquid outlet means includes a slot disposed circumferentially about the inner surface of the annular sleeve whereby a continuous impingement jet of liquid is provided against the pad of the paint roller.
Yet another feature of one embodiment is the inclusion of a threaded cylindrical portion oriented generally parallel to the annular sleeve such that the paint roller may be moved vertically through the annular sleeve. As previously discussed, this causes the water or cleaning liquid used to flow evenly down and around the roller pad so as to completely flush away the paint or other substance present rather than letting the paint settle on one side of the roller pad as is the tendency when the roller is moved in a horizontal direction through the paint roller cleaning apparatus taught by the device shown in FIG. 1 when mounted to a faucet.
Yet another advantageous feature of the preferred embodiment of the present invention is the inclusion of scrubber elements circumferentially positioned about the inner surface of the annular sleeve. By rotating the roller with a left and right twisting motion as it is moved vertically through the cleaning apparatus, a scrubbing action is imparted to the roller pad or fabric cover. As previously discussed, this facilitates cleaning of hard to clean roller pads.
Additionally, the scrubber elements can be used to effectively fluff up a dry roller fabric cover. The fabric of a roller cover after being washed, has a tendency to dry in a matted state. The scrubber elements can be used to fluff up the fabric by moving the roller fabric cover through the cleaning apparatus with a vertical and left and right twisting action.
These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects obtained by its use, reference should be had to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, in which like reference numerals and letters indicate corresponding parts throughout the several views,
FIG. 1 is a perspective view of a prior art paint roller cleaning apparatus;
FIG. 2 is a perspective view of an embodiment of a paint roller cleaning apparatus in accordance with the principles of the present invention;
FIG. 3 is a cross sectional view taken generally along line 3--3 of FIG. 2;
FIG. 4 is a perspective view of the embodiment shown in FIG. 2 in use on a faucet, the roller pad being removed from the handle portion of the roller; and
FIG. 5 is a perspective view of the embodiment shown in FIG. 2 in use on a garden hose, the roller pad being mounted on the handle portion of the roller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a prior art paint roller cleaning apparatus is shown, the cleaning apparatus being generally designated by the reference numeral 10. The paint roller cleaning apparatus includes an annular sleeve 12 having an inner surface 14 and an outer surface 16 spaced therefrom. The inner and outer surfaces 14, 16 define a space for liquid passage. Positioned circumferentially about the annular sleeve 12 on the inner surface 14 is a slot 18 defining a liquid outlet. Interconnected to the outer surface 16 and extending radially therefrom is a threaded cylindrical portion 19 defining a liquid inlet passage in communication with the passage between the inner and outer surfaces 14, 16. Accordingly, the paint roller cleaning apparatus shown in FIG. 1 can be threadedly attached to a source of cleaning liquid. However, when attached to a source of cleaning liquid, the annular sleeve 12 has a horizontal orientation such that the paint roller is moved horizontally through the paint roller cleaning apparatus 10. Accordingly, the paint or other substance embedded in the paint roller pad has a tendency to settle at the bottom of the cleaner pad due to the effect of gravity. Additionally, when the paint roller cleaning apparatus 10 is attached to a faucet or the like of a cleaning tub, the sides of the tub have a tendency to interfere with the horizontal movement of the paint roller pad.
Additionally, the inner surface 14 of the paint roller cleaning apparatus 10 is relatively smooth. Accordingly, other than the impinging jet-like stream from the slot 18, there is no scrubbing action imparted to the roller pad.
Illustrated in FIGS. 2 and 3 is a preferred embodiment of the present invention, generally being designated by the reference numeral 20. The paint roller cleaning apparatus shown includes an annular sleeve 22 having an inner surface 24 and an outer surface 26 radially spaced therefrom so as to define an annular fluid passage 28. The annular sleeve 22 includes an enclosed top end 30 and an enclosed bottom end 32. Interconnected to the outer surface 26 is a portion 34 providing for attachment of the paint roller cleaning apparatus 20 to a source of water or other cleaning liquid. The portion 34 defines a passageway 36 in communication with the annular passage 28. In addition, extending circumferentially about the annular sleeve 22 on the inner surface 24 is a slot 38 defining a passageway out of the annular sleeve 22. Accordingly, as illustrated in FIG. 3, water or other cleaning liquid as generally illustrated by the arrows 40 is able to flow from the source of the water through the passage 36 into the annular passage 28 and out the slot 38 when the cleaning apparatus 20 is suitably interconnected to a source of water or other cleaning liquid. The portion 34 includes an internally threaded cylindrical portion 42 enabling the cleaning apparatus 20 to be threadedly attached to a faucet or garden hose or the like.
As generally illustrated in FIG. 3, the cleaning apparatus 20 includes a plurality of spaced apart, axially extending scrubber elements 44 on the inner surface 24 along the lower portion thereof. The scrubber elements 44 are separated by recessed portions 46 of greater width than the scrubber elements 44. In the embodiment shown, the scrubber elements 44 extend from the bottom end 32 to just below the circumferential slot 38. Further, the scrubber elements 44 have an inwardly facing surface which is flush with the inner surface 24.
One embodiment of the present invention is made from a molded plastic material. The cleaning apparatus 20 being molded in two separate sections 48a and 48b which are suitably secured to one another generally at the location 50 by various methods such as sonic welding.
The embodiment of the present invention shown in FIGS. 2-3 is illustrated in actual use in FIGS. 4 and 5. In FIG. 4, the cleaning apparatus 20 is threadedly interconnected to the end of a faucet 52 whereas in FIG. 5, the cleaning apparatus is threadedly interconnected to the end of a garden hose 54. In FIG. 4, the operator is using his or her hands to vertically move, as illustrated by the arrow 58, and twist, as illustrated by the arrow 60, a roller pad 55 in the cleaning apparatus 20 whereas in FIG. 5 the user is using a handle portion 56 of the paint roller to vertically move and twist the roller pad 55 in the cleaning apparatus 20. In FIG. 5, the user is supporting the cleaning apparatus 20 with his or her hand as opposed to FIG. 4 wherein the cleaning apparatus 20 is supported by the faucet 52. It is anticipated that a user might use his or her hand for movement of the roller pad 55 for more difficult cleaning jobs.
The present invention thus provides a cleaning apparatus which does not damage the roller core. In addition, cleaning apparatus 20 forces the water or other cleaning liquid directly into and through the roller pad or fabric cover and flushes the paint out from within the fabric cover or pad at the core of the roller as well as along the sides thereof. In addition, the preferred embodiment of the present invention enables the roller pad to be moved in a vertical motion. This allows the water to run down and around the pad flushing the paint off rather than letting it settle and run back into the fabric cover. The preferred embodiment of the present invention provides a scrubbing action upon rotating the roller pad therein with a left and right motion. This is particularly efficient for hard to clean roller pads wherein the paint or other substance has dried onto the fabric cover.
It will be appreciated that alternate embodiments in keeping with the principles of the present invention might be utilized. For example, the circumferential slot 38 might be replaced by a plurality of apertures so as to provide a plurality of impinging water or liquid streams onto the pad of the paint roller. In addition, the paint roller cleaning apparatus might include a handle thereon so that it may be easily used when connected to a hose. Furthermore, with some types of paint and other substances, it may be advantageous to supply detergent along with the cleaning fluid to assist with the cleaning of the paint roller and therefore in various embodiments of the present invention, there may be included detergent dispensing structures.
It will be appreciated from the above that using an annular sleeve fitting with an interference fit around the cylindrical shape of a paint roller pad in effect limits egress of cleaning liquid from the circumferential slot 38 so that the cleaning fluid or water is forced more effectively to enter deep within the porous structure of the pad and hence cause a much more effective cleaning action.
Furthermore, the present invention also relates to the method of cleaning the pad of a roller which includes the steps of locating the pad with an interference fit within the annular sleeve 22 of a paint roller cleaning device, causing a cleaning fluid or water under pressure to eject through the circumferential slot 38 and into the roller pad, and moving the roller pad vertically and in a right and left twisting action.
It is to be understood, however, that even though numerous characteristics and advantages of the invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A paint roller cleaning device (20) comprising an annular sleeve (22) adapted to have an interference fit with a pad on a roller (55) of a paint roller. The paint roller cleaning device (20) includes liquid passage means (28) within the annular sleeve (22), liquid entry means (36) to said liquid passage means (28) and liquid outlet means (38) communicating with the liquid passage means (28) on the inner surface (24) of the annular sleeve (22). A plurality of scrubber elements (44) are positioned circumferentially about the inner surface (24) of the annular sleeve (22) along a longitudinal portion thereof. The liquid entry means (36) includes a threaded cylindrical portion (42) in parallel orientation with the annular sleeve (22).
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of pending International patent application PCT/EP2007/064341 filed on Dec. 20, 2007 which designates the United States and claims priority from German patent application 10 2006 062 240.5 filed on Dec. 22, 2006.
FIELD OF THE INVENTION
The present invention relates to a releasable coupling, preferably for releasable coupling connection of drive and output elements such as shaft ends, comprising a first and a second coupling part with means for transmitting torque.
BACKGROUND OF THE INVENTION
A large number of couplings of this kind of different designs are known. However, if said couplings are couplings which can be connected with a view to being released, complex additional devices are sometimes required for the engagement and disengagement procedures. Secondly, that is to say if the couplings are permanently closed couplings, establishing and releasing the coupling connection is often only possible by way of an assembly/disassembly procedure. Known in particular are couplings of which the two coupling parts have to be screwed to one another in order to transmit torque. This is only possible when, depending on the installation position of the coupling, there is sufficient installation space and an adequate degree of accessibility, but this is not always the case in the desired manner and/or leads to structural constraints. Furthermore, such assembly (disassembly) often also takes an undesirable amount of time.
Against this background, it is an object of the invention to develop the coupling cited in the introductory part in a manner which is advantageous for use, so that in particular the abovementioned disadvantages may be avoided as far as possible.
SUMMARY OF THE INVENTION
According to the invention, the object is solved first and foremost in conjunction with the features that the first coupling part has a projection which extends in the direction of the geometric axis of rotation (that is to say the rotation axis or longitudinal axis of the coupling) and in the lateral surface of which a first peripheral groove, in particular an annular groove, is formed, that the second coupling part has a recess, the cross-section of which is adapted as a receptacle for the projection and in the lateral surface of which a second peripheral groove, in particular an annular groove, is formed, that a ring-like locking member is provided, which is elastically deformable in terms of the contour of its open or closed periphery, it being possible to insert said locking member into a peripheral groove or selectively into one of the two peripheral grooves when the coupling parts are in the disconnected state, and the contour of said locking member protruding out of this peripheral groove when the two coupling parts are in the disconnected state. It is especially preferred that, in the state in which the two coupling parts are disconnected, the locking member takes up, in the peripheral groove into which it has been inserted, a shape and/or position such that it automatically or necessarily protrudes in a resiliently flexible manner out of said groove. The coupling parts of a coupling of this type can be connected by the projection being inserted into the recess in the longitudinal direction of the coupling, as a result of which the locking member is deformed in a temporary and resilient manner by means of the other coupling part by virtue of the shaping of this other coupling part, that is to say the locking member is either resiliently expanded or compressed depending on the peripheral groove selected for the insertion of the locking member, after which the locking member, while providing axially aligned orientation of the two peripheral grooves, also automatically engages in the further peripheral groove under the prestress of the locking member. The connection state is accordingly achieved by a simple relative movement of the two coupling parts along their geometric axis of rotation or longitudinal axis, it being possible for a small axial movement space to be sufficient for this purpose. By virtue of the prestressed connecting element snapping into the second peripheral groove, the connection state is automatically locked, so that no tool is required for this purpose. It is possible to release the coupling parts by exerting a force on one or both coupling parts counter to the connecting direction, said force being sufficient to produce a force action on the peripheral groove or grooves for renewed resilient deformation of the locking member with radial movement into only one of the two peripheral grooves. It is therefore possible to release the coupling parts with only minimal space for movement and without tools. In this case, the invention provides the possibility of various configurations in order, in particular by virtue of the shaping and dimensioning of the projection and/or recess and of the two peripheral grooves in accordance with the locking member, to determine how high the two force effects required for connecting and for releasing purposes should be (these can be preferably of different magnitudes) or whether accommodation of the locking member in the peripheral groove of the first or second coupling part is advantageous in the released state.
In terms of shaping and size, the locking member is preferably realised such that it can be inserted into the second or radially outer peripheral groove, and that the inner contour of said locking member protrudes radially inward out of the second peripheral groove into the cross-section of the first recess when the two coupling parts are in the released state, and engages in the first or radially inner peripheral groove when the two coupling parts are in the connected state. As an alternative, it would be possible for the locking member to be insertable into the first peripheral groove and for the outer contour of said locking member to protrude outward from the first peripheral groove when the two coupling parts are in the released state, and to engage in the second peripheral groove also, when the two coupling parts are in the connected state. It is further preferred for the cross-sections of the projection and of the recess to be matched to a common clearance or transition fit and to be bounded in a circular manner, preferably transverse to the geometric axis of rotation or to the longitudinal axis of the coupling. As a result, the projection and the recess can exert a centering effect on the two coupling parts, depending on the configuration. An advantageous configuration can be seen when the locking member used is a round-wire circlip, preferably comprising spring steel, which is open on the periphery. On account of its peripheral opening and the elastic material properties, said round-wire circlip has the desired resiliently flexible peripheral contour, that is to say its diameter or cross-section can be temporarily increased or reduced in size in accordance with the force effect against its resilient restoring force. Furthermore, the round wire-cross-section of such circlips provides advantages for the plug-type coupling according to the invention since it is possible to determine in conjunction with various groove cross-sections of the peripheral, or in particular annular, grooves, the axial force that is to be exerted on the coupling part or the two coupling parts until the desired elastic deformation of the locking member is reached on account of the transmission of force by the first and/or second peripheral, or in particular annular, groove. As an alternative, use may be made of other types of circlips and locking rings and also securing elements of different configuration, in particular also corresponding to the cross-sections of projections and recesses that have a peripheral contour which deviates from the circular line, for example an oval or polygonal or even a non-round or square peripheral contour. In addition, a locking member may be used which has an oval, polygonal or angular cross-sectional shape instead of a round-wire or a circular cross-sectional shape. The material used may be, for example, a plastic, in particular glass- or carbon-fiber-reinforced plastic, or, for example, a bimetal realisation.
A practical configuration can be seen in the first peripheral groove having, transverse to the peripheral direction, that is to say in cross-section, a rounded cross-section, preferably a cross-section which is in the form of a portion of a circle, more preferably a cross-section which is in the form of a semicircle. In this context, it is further preferred for the second peripheral groove to have, transverse to the peripheral direction, an angular cross-section, preferably a rectangular cross-section, more preferably a square cross-section. A cross-section which is in particular rectangular or square, the corners of which are rounded or chamfered, is also possible. The size of the corner radius of the rounded portion can be selected as desired so that the cross-sectional shape approximates to a semicircle or corresponds to a semicircle. When the connected coupling parts are being released, depending on the cross-section and also depending on the depth to which the locking member engages into the two axially aligned peripheral grooves, conversion of the axial disconnection force into a radial force of comparatively greater magnitude is facilitated, by the, preferably radially inner, peripheral groove of rounded cross-section compared to the second peripheral groove, so that the locking member is radially expanded (that is to say is not radially constricted) and moves to the second, preferably radially outer peripheral groove. This may be still further assisted by virtue of the fact that the locking member has, transverse to the peripheral direction, the round cross-section which has already been discussed, of which round cross-section the cross-sectional radius preferably corresponds to or is slightly less than the radius of the rounded portion of the first peripheral groove and/or of which round cross-section the diameter may be approximately equal to or somewhat less than the width of the second peripheral groove. Provision is preferably made for the locking member to be inserted into the second peripheral groove, which is formed in the lateral surface of the recess, before the two coupling parts are connected, so that the inner contour of said locking member initially projects out of the second peripheral groove into the cross-section of the recess. In order to facilitate radial expansion when the two coupling parts are connected, it is possible for the cross-section of the projection to be tapered, preferably tapered in a conical and/or rounded manner, at the edge of the projection which faces the base of the recess when the coupling parts are joined together. The tapered portion, which is for example conical, effects force transmission that facilitates the radial expansion of the locking member, depending on the cone angle, so that only a comparatively low axial force is required for assembling and for connecting the two coupling parts, depending on the specific configuration. Secondly, the level of the axial force which is required to then disconnect the two coupling parts depends on the cross-sectional shapes of the two peripheral grooves and of the locking member. It is preferred for the axial force required to disconnect the coupling parts to be greater in magnitude than the axial connecting force, this being achieved by suitable configuration of the coupling parts and explained in greater detail in the text which follows. Said tapered portion may preferably extend as far as an edge cross-section or edge diameter of the projection, this corresponding approximately to or being slightly smaller than the smallest cross-section or cross-sectional diameter of the projection which is left by the first peripheral groove. In a preferred configuration in which the projection and the recess have a circular cross-section and the periphery of the locking member at least substantially follows a circular contour, provision may be made, in the unloaded state of the locking member, for the outside diameter of said locking member to be less than the diameter of the second peripheral groove at the groove base of said groove, and to be greater than the diameter of the recess. This provides a sufficient gap, in particular an annular gap, in the second peripheral groove, firstly radially outside the locking member, so that the locking member can expand to the necessary degree during the process of connecting the coupling parts. Secondly, the locking member is held in the second peripheral groove in a captive manner as early as after being inserted into said second peripheral groove. It is further preferred that, in the unloaded state of the locking member, the inside diameter of said locking member corresponds to or is slightly greater or less than the diameter of the first peripheral groove at the groove base of said groove. This has the effect that the circlip or locking ring is located in the first peripheral groove without appreciable radial force when no axial force acts on the coupling parts. Secondly, direct transfer of force is achieved in the event of the circlip or ring being accommodated in this way with virtually no radial play. It is also preferred that, at least in the state in which the two coupling parts are connected, the inside diameter of the locking member corresponds to the diameter of the first peripheral groove at the groove base of said groove, and the outside diameter of the locking member is greater than the diameter of the recess. The abovementioned, preferred features have the result that the axial force required to connect the two coupling parts is smaller in magnitude than the axial disconnection force. A plug-type coupling of this type is therefore preferably suitable for applications in which assembly is to be performed in the simplest manner possible and with as little force as possible, but on the other hand the resiliently elastic snap-action connection or locking which serves for connection purposes is to sustain certain axial forces which occur during operation without the connection coming apart. Applications of this type can be found, for example, in the drive of worm conveyors or worm gears, or, for example, also in obliquely toothed gear mechanisms. Even if the above-described cross-sectional shapes and diameters of the first and second peripheral grooves and of the locking member are preferred embodiments, it goes without saying that a wide variety of modifications of these embodiments are also possible within the scope of the invention. For example, it is possible to form the cross-sectional shape of the first peripheral or annular groove to be angular, in particular with rounded portions or chamfers provided in the corners and/or to form the cross-sectional shape of the second peripheral or annular groove to be round.
According to a further aspect, it is also preferred for, on the first coupling part, the projection to extend from a connection end, which is preferably in the form of a disk and can serve for connection to a drive-side or output-side shaft end, with its lateral surface concentric with the geometric axis of rotation, that is to say with the longitudinal or rotational axis of the coupling. As an alternative, extension of the projection, and accordingly also of the recess, parallel to and at a spacing from the said rotational or center axis, that is to say in an eccentric manner, would also be possible. In conjunction with an eccentric recess, which has a matching cross-section, an eccentric projection of the above type also forms an eccentric driver, the positively-locking connection of which can be used to transmit torque. This means that an eccentric projection of this type, in conjunction with an eccentric recess, would be suitable both for releasable axial connection of the coupling parts and also, by performing a double function, for transmitting torque. Torque transmission by means of the projection and the recess, which have the peripheral groves, would also be possible by said projection and said recess being formed centrally in relation to the center axis but in each case having a mutually matching non-round cross-section, for example an oval, polygonal or angular cross-section. If the cross-section of the projection and the recess deviates from a circular shape, the peripheral profile of the peripheral grooves may deviate from a circular line and to this degree be matched to the peripheral profile of the projection and recess in a suitable manner. The ring-like locking member may also be matched to this, that is to say may have, for example, an oval, polygonal or angular peripheral profile in the unloaded state.
However, it is preferred within the scope of the invention for a separate eccentric projection and a separate eccentric recess to be provided for transmitting torque. It is possible for one of the coupling parts to have at least one eccentric projection which extends parallel to and at a spacing from the axis of rotation of the coupling, and for the other coupling part to have at least one eccentric recess for accommodating the eccentric projection, it being possible for the eccentric projection and the eccentric recess to be assigned to the first and second coupling parts in different ways. It is possible for the cross-sections of the eccentric projection and of the eccentric recess to be matched to a common clearance or transition fit as a result of which virtually play-free torque transmission in both directions of rotation is possible. It is also preferred for the two cross-sections of the eccentric projection and the eccentric recess to be bounded in a circular manner, or, for example, in an oval, polygonal or similar manner, transverse to the axis of rotation of the coupling, so that edges are avoided and also high torques can be transmitted without damage. It goes without saying that it is also possible for a plurality of such eccentric projections and a plurality of matching eccentric recesses to be provided for transmitting torque. A possible alternative to a separate eccentric projection and a separate eccentric recess can be seen by there being, for torque transmission, a separate rotary positively-locking projection and a matching rotary positively-locking recess, said rotary positively-locking projection and rotary positively-locking recess having a cross-section which deviates from a circular shape and therefore not necessarily being disposed eccentric to the center axis or rotation axis of the coupling for torque transmission purposes. An oval, polygonal or, under certain circumstances, also an angular cross-section are possible. A preferred configuration can be seen when the eccentric projection or rotary positively-locking projection extends starting from the tapered edge of the, in particular concentric, projection which has the first peripheral groove, and the eccentric recess or rotary positively-locking recess extends starting from the base of the, in particular concentric, recess which has the second peripheral groove. As a result, the snap-action connection or locking is first produced when the eccentric projection or rotary positively-locking projection enters the eccentric recess or rotary positively-locking recess. The first and the second coupling part may be matched to flanges or the like in a variety of ways for connection to drive or output elements, for example shafts with a solid or hollow cross-section. The first coupling part can preferably have a disk-like connecting flange, from which the projection with the peripheral groove rises. The second coupling part can preferably have a central hole, which opens into the recess, for accommodating and fixing, possibly, an (output) shaft in the case of a bell or cup-like overall design.
The invention also comprises a worm for a conveyor, preferably for a sampler, with the worm flight being fixed to a worm shaft that runs centrally in the longitudinal direction, and the worm shaft being connected to a coupling part of the coupling according to the invention, preferably to the second coupling part of said coupling. Furthermore, the invention comprises a sampler which comprises a worm conveyor that has a worm of the abovementioned type. In this respect, a worm of this type or a sampler of this type may also form the subject matter of independent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail below with reference to the accompanying figures which show preferred exemplary embodiments of the invention, and in which:
FIG. 1 shows a longitudinal section through the coupling according to the invention, according to a preferred embodiment in the connected state;
FIG. 2 shows a section along section line II-II in FIG. 1 ,
FIG. 3 shows a plan view of the locking member illustrated in FIG. 1 ;
FIG. 4 shows a sectional view along section line IV-IV in FIG. 3 ;
FIG. 5 shows a further longitudinal section of the coupling shown in FIG. 1 , at the beginning of the connection procedure;
FIG. 6 shows a further longitudinal section of the connecting procedure, at a later point in time;
FIG. 7 shows a perspective view of the coupling according to FIGS. 1 to 6 in conjunction with a conveyor worm;
FIG. 8 shows the position from FIG. 7 from another viewing direction;
FIG. 9 shows a longitudinal section of the components shown in FIGS. 7 , 8 in the connected state; and
FIG. 10 shows a preferred application example of the coupling shown in FIGS. 1 to 6 in a sampler with a conveyor worm.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a longitudinal section of a preferred exemplary embodiment of the coupling 1 according to the invention, said longitudinal section running through the central geometric axis of rotation 2 of said coupling. The coupling 1 comprises a first coupling part 3 and a second coupling part 4 , these coupling parts each being integrally formed. In this case, the first coupling part 3 has a shape which is formed from a plurality of disk segments, so that it could also be called a coupling disk. In contrast, the second coupling part has inner recesses that adjoin one another, the cross-sections of which are matched to the disk segments, so that this can be called a coupling bell overall. On the first coupling part 3 , the disk segment 5 of largest diameter which is axially at the edge forms a connecting flange for connection to a matching mating flange of a drive or output element, preferably to a drive flange. To this end, two through holes 9 , which are opposed and at the edge and through which screws 10 are brought in order to be screwed into the thread of the mating flange (cf. FIG. 10 ), are located at that edge 8 which projects beyond the adjoining disk segments 6 , 7 . In addition, a central through hole 9 is provided with a screw 10 , the screw head of said screw being recessed into the disk segments 6 , 7 of reduced diameter. For the purpose of connection to a drive or output element, preferably for connection to an output-side hollow shaft 11 which is illustrated by way of a detail of an end, the second coupling part 4 has a central through hole 12 which extends as far as said recesses. In the selected exemplary embodiment, the three disk segments 5 , 6 and 7 each have a circular cross-section, with the diameter in each case being reduced from disk segment 5 to disk segment 6 and from there to disk segment 7 . In this respect, the central disk segment 6 forms a projection 13 which extends in the direction of the geometric axis 2 from the connecting segment 5 , with a first peripheral groove 15 with a semicircular cross-section (also see FIGS. 5 and 6 ) being let into in the cylindrical outer surface 14 of said projection 13 . In the selected example, but not necessarily, the peripheral groove is a closed or continuous annular groove of circular shape on the periphery. The second coupling part 4 has a recess 16 , the similarly round cross-section of which is adapted as a receptacle for the projection 13 with a clearance or transition fit and into the cylindrical lateral surface 17 of which a second peripheral groove 18 is made. In the selected example, but not necessarily, the peripheral groove is also here an annular groove which runs in a circular and closed manner on the periphery. In terms of their lateral surfaces 14 , 17 , the projection 13 and the recess 16 are disposed concentric with the center line 2 . In the connected state shown in FIG. 1 , the two coupling parts 3 , 4 can be releasably connected in a resilient and latching manner by means of a locking member 19 which is inserted into the two peripheral grooves 15 , 18 in the axial direction, that is to say in the direction of the axis of rotation 2 . As illustrated in FIGS. 3 , 4 , the locking member is a spring-steel round-wire circlip which is open on the periphery. While the first peripheral groove 15 has a semicircular cross-sectional shape transverse to its peripheral direction (cf. FIG. 5 ), the second peripheral groove 18 has a rectangular cross-sectional shape, being virtually square in the selected exemplary embodiment. On its cross-section which is oriented transverse to the peripheral direction, the locking member 19 has a cross-sectional radius r which corresponds to the radius R of the rounded portion of the first peripheral groove 15 . The width B of the second peripheral groove 18 in the axial direction is only slightly (and in the figures therefore not visibly) greater than the diameter d of the cross-section of the locking member 19 . The function of this releasable axial coupling or locking device which is formed from the projection 13 with a peripheral groove 15 , the recess 16 with a peripheral groove 18 and the locking member 19 , will be discussed in even greater detail in the text which follows.
With reference to FIGS. 1 and 2 , it is also clear that the first coupling part 3 has an eccentric projection 20 which is formed by the disk segment 7 of smallest diameter. As shown in FIG. 2 , this eccentric projection extends with the eccentricity e parallel to and at a spacing from the axis of rotation 2 of the coupling. The second coupling part 4 has an eccentric recess 21 , which is matched to the eccentric projection 20 with a clearance or transition fit, in order to accommodate the eccentric projection 20 . The eccentric projection 20 extends starting from a tapered edge of the projection 13 that has the peripheral groove 15 , and the eccentric recess 21 extends starting from the base of the concentric recess 16 that has the second peripheral groove 18 . In this respect, the eccentric projection 20 and the eccentric recess 21 form a positively-locking, releasable torque transmission device.
The round-wire circlip shown in FIGS. 3 , 4 has, in the unloaded state, an open periphery which follows a circular line. In the selected example, the width X of the peripheral opening is approximately ¼ of the inner ring diameter D 2 .
Bringing in FIGS. 5 and 6 , the functioning of the axial connection device and the establishment and release of the axial coupling connection will now be described in greater detail. FIG. 5 relates to a first state in which the two coupling parts 3 , 4 are not yet locked in the axial direction. The locking member 19 is initially inserted into the peripheral groove 18 of the coupling part 4 such that it can still move. In this unloaded state of the locking member 19 , the outside diameter D 1 of said locking member is less than the diameter D 3 of the second peripheral groove 18 at the groove base of said peripheral groove, but is greater than the diameter D 4 of recess 16 , so that the result is captive accommodation, and the inner contour of the locking member 19 protrudes out of the peripheral groove 18 (at least by way of a portion of its periphery, depending on the exact position) radially inward into the recess 16 . In order to connect the two coupling parts 3 , 4 , the projection 13 is initially inserted into the recess 16 as far as an axial depth which is somewhat less than that in FIG. 5 , and the coupling parts 3 , 4 are rotated in relation to one another until the eccentric projection 20 enters the eccentric recess 21 . The position shown in FIG. 5 in which the conical tapered portion 22 of the projection 13 butts, by way of its edge or transition to the eccentric projection 20 , against the round-wire circlip 19 is only reached as a result of the above action. In the selected example, the cone angle of the tapered portion 22 is, by way of example, 30°, but, in a deviation from this, other cone angles and/or rounded portions can be realized. The coupling part 3 can be pushed further into the coupling part 4 by applying an increased axial force. In the process, the tapered portion 22 widens the locking member 19 to such a degree that said locking member can move up onto on the lateral surface 14 , cf. FIG. 6 . Upon further insertion, the connection state in FIG. 1 is reached, in which the locking member 19 latches into the radially inner peripheral groove 15 on account of its spring action and radial prestress. In this connection state, the inside diameter D 2 of the locking member 19 corresponds to the diameter D 5 of the first peripheral groove 15 at the groove base of said peripheral groove, and the outside diameter D 1 of the locking member 19 is greater than the diameter D 4 of the recess 16 . On account of the described size and diameter ratios, one half of the cross-sectional shape of the round-wire circlip 19 is situated in each of the annular grooves 15 , 18 in the selected exemplary embodiment. Furthermore, in the unloaded state of the locking member 19 also, the inside diameter D 2 of said locking member 19 corresponds to the diameter D 5 of the first peripheral groove 15 at the groove base of said peripheral groove in the selected exemplary embodiment. Disconnection of the coupling parts 3 , 4 is effected in analogous manner by reversing the relative displacement, an axial force of greater magnitude being required however for this purpose in the desired manner on account of the selected cross-sections of the annular grooves and of the round-wire circlip. FIG. 1 also shows that the axial position of the first and second peripheral grooves 15 , 18 is selected or determined such that the projection 13 and the eccentric projection 20 virtually completely fill the associated recesses 16 , 21 in the connection state shown, but with a small axial gap remaining at the end, and also at the flange 8 , in order to avoid any problems.
FIGS. 7 to 9 show the coupling 1 described with reference to the preceding figures in conjunction with a worm 23 which serves to convey, for example, bulk materials. The worm comprises a worm flight 24 which is fixed in a manner which is known per se on a central worm shaft 25 of hollow cross-section. At the drive end, the worm shaft 25 enters the hole 12 (cf. FIG. 1 ) of the second coupling part 4 and can be secured, for example welded, (in a manner which is not illustrated in greater detail) to the coupling part 4 in the axial direction and the peripheral or rotational direction. In this respect, the worm 23 is further developed, according to the invention, such that it is connected to the second coupling part 4 and to the coupling 1 according to the invention.
FIG. 10 shows, in a longitudinal section which is schematically simplified in part, a preferred application example, which lies within the scope of the invention, of the coupling or worm according to the invention which is described with reference to the preceding figures. The apparatus shown is what is known as a sampler, in which the worm 23 which is described with reference to FIGS. 7 to 9 serves to feed loose sample material, such as for example cement, to a mixer 27 . A geared motor 28 drives a mixer agitator 29 and, via this, the worm shaft 25 by means of the axially interpositioned coupling 1 according to the invention. The sample material, for example cement, falls into a chute 30 (conveying with negative pressure) and passes through sample-capturing openings 31 into a casing pipe 32 and, in said casing pipe, into conveying spaces in the worm 23 . The openings 31 may be, for example, round, elliptical, angular or in the shape of elongate slots and be axially parallel (or not) depending on the position. A cement sample is conveyed by the worm 23 in the casing pipe 32 into the mixer 27 by rotating the worm shaft 25 . A pneumatic cylinder 33 closes a sample discharge 35 of the mixer 27 by way of the closure plunger 34 . During sampling, the mixer agitator 29 thoroughly mixes the cement sample in the mixer 27 . If the mixer 27 is over-filled, the sample material is conducted to the outlet 38 through the overflow 36 and the overflow channel 37 . A sample can be taken from the mixer 27 either by means of the device for manual sampling 39 or through the sample discharge 35 . The plug-type coupling 1 according to the invention allows the worm 23 to be coupled to and uncoupled from the mixer 27 , and in particular also allows retrofitting of said worm to said mixer. In the selected exemplary embodiment, the second coupling part 4 (that is to say the coupling bell) is connected to the worm shaft 25 such that it cannot be released. The worm itself is welded to the worm shaft. For mounting or connecting purposes, the first coupling part 3 (or the coupling disk) on the mixer agitator 29 is located on the drive shaft of the geared motor 28 , or is mounted there on a once-off basis. In the second coupling part 4 , the round-wire circlip (locking member 19 ) is inserted into the peripheral groove 18 in said coupling part. The worm 23 is inserted, with the worm shaft 25 and the coupling bell 4 , in the axial direction through a mixer flange 41 and the connection pipe 40 (guide pipe), and the second coupling part 4 is pushed onto the first coupling part 3 in a centering manner until the desired coupling connection is established in the manner described above. In this case, it is possible to sense the position of the eccentric projection 20 by rotating the worm 23 and then to bring the coupling 1 into latching engagement by gentle pressing, for example by striking the worm with a plastics hammer. The plug-type coupling 1 can be released again by pulling strongly on the worm 23 . In the manner described, the worm can also be coupled to and uncoupled from the mixer, for example for cleaning purposes, any number of times in the described simple and space-saving manner, even though the drive-side shaft end is accessible only through the narrow connection pipe 40 . The casing pipe 42 can be fixed to the mixer by way of a casing pipe flange 43 and the mixer flange can be firmly screwed to the guide pipe. A further casing pipe flange 44 is used to attach the casing pipe to a mating flange 45 which is screwed to the chute 30 . This construction makes clear that the worm 23 can be coupled and uncoupled after removal of the chute 30 even with the casing pipe 42 fitted. On account of the worm conveying direction selected in FIG. 8 , an axial force which is directed away from the coupling 1 acts on the worm 23 during operation. The locking device of the coupling 1 is provided in the above-described manner such that it can withstand the axial force during operation but on the other hand the coupling 1 can still be manually released.
All disclosed features are (in themselves) pertinent to the invention. The disclosure content of the associated/accompanying priority documents (copy of the prior application) is also hereby incorporated in full in the disclosure of the application, including for the purpose of incorporating features of these documents in claims of the present application.
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A releasable coupling, including a first and a second coupling part for transmitting torque, where the first coupling part has a projection which extends in the direction of the geometrical axis of rotation and in the circumferential surface of which a first peripheral groove is embedded, that the second coupling part has a recess which is matched in cross section to a receptacle on the projection and in the circumferential surface of which a second peripheral groove is embedded, that an annular securing element is provided, the securing element being elastically deformable with respect to the contour of its open or closed periphery and, in the separated state of the two coupling parts, being insertable into one or optionally into one of the peripheral grooves and the contour of which, in the separated state of the two coupling parts, projecting out of the peripheral groove.
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BACKGROUND
[0001] Increasingly, digital assets are stored on computing devices such as desktop computers, servers, phones, handheld devices, etc. Digital assets continue to grow in size and significance such as by users digitally storing their photo collections, personal video libraries, music collections, documents, etc. There is a need to store and maintain the digital assets for longer terms. Many digital devices designed to capture digital media store the media on temporary (e.g. a hard drive or flash memory) storage, compounding the requirements for longer term storage. Moreover, the risk of device failure (e.g. hard drive failure), system disruption (e.g. natural disaster, computer virus infection, etc.), and user failure (e.g. a user failing to conform to a required protocol to provide reliable backup) in turn require alternative measures to maintain reliable long term storage of digital assets. Accordingly, there is a need for increasing the reliability of storing such data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 illustrates logical elements in an example a resource sharing community of the invention;
[0003] FIG. 2 illustrates logical elements of a peer in a resource sharing community;
[0004] FIG. 3 illustrates logical elements of a governor node in the resource sharing community of FIG. 1 ;
[0005] FIG. 4 illustrates logical elements of an agent module associated with a peer in the configuration of FIG. 1 ;
[0006] FIG. 5 is a flow diagram illustrating peer initiation steps in the resource sharing community of FIG. 1 ;
[0007] FIG. 6 is a flow diagram illustrating further details of the rule processing step of FIG. 5 ; and
[0008] FIG. 7 is a flow diagram illustrating the operation of an agent module on a peer when observing an event.
SUMMARY OF THE INVENTION
[0009] Therefore, in accordance with the invention there is provided a method for facilitating a digital community which provides shared resources across a wide collection of users, which, for example, allows users to exploit reliable longer term storage for their digital assets. In one embodiment, the digital community conforms to a set of rules, or community rules, so as to enhance cooperation between users and increase storage reliability.
[0010] In another embodiment, the invention provides a data storage system for increasing the reliability of data stored on a peer system. The system includes a plurality of peer computer systems, whereby each peer computer system including computer system hardware, communication interface, applications, and data. The system also provides, for each peer computer systems, a storage profile, which is generated by reference to at least attributes relating to the hardware and software associated with each peer. The system further includes an agent module executing on each peer system to facilitate storage of data of a client peer from the plurality of peer computer systems on a service peer from the plurality of peer computer systems in response to a request for storing data from the client peer. In this embodiment, the service peer is selected by reference to the storage profile associated with the service peer and the storage profile associated with the client peer.
[0011] In yet another embodiment, the system further includes a governor node server, which provides for the selection of a service peer for a client peer making a request for storing client peer data. In this embodiment, the governor node transmitting instruction to an agent module associated with each of the client peer and the service peer to facilitate the storage of client peer data on the service peer.
DETAILED DESCRIPTION
[0012] For the purposes of the discussion the following terms shall have the meaning as provided below:
[0013] Peer: a device on a network that can store and retrieve digital assets; a desktop computer attached to the internet; alternatively, a server, a handheld computer, or a phone.
[0014] User: the person who logically owns and manages a peer.
[0015] Client peer: a peer on a network that is requesting services, including backup storage.
[0016] Service peer: a peer on a network that is providing services, including providing storage for backup. Note that a peer can assume both the role of a client peer and a service peer, depending on the conducted operation.
[0017] Digital community: a collection of peers sharing a network and conforming to a set of rules dictating services performed on behalf of other peers.
[0018] Profile: facets of a peer, including amount of storage available, amount of storage required to be backed up, storage access time, storage availability, geographic location, operating system, and prevalent applications.
[0019] Citizenship: the reputation of a peer in a digital community.
[0020] Currency: the amount of storage a peer can reliably provide weighted by profile and citizenship
[0021] Community rules: the set of rules governing peer services in a digital community.
[0022] Governor: a service that enforces community rules in a digital community.
[0023] Confederated model: a resource sharing network arrangement where peer systems enforce community rules in a distributed pashion.
[0024] Federated model: a resource sharing network arrangement where a centralized governor node participates in enforcement of community rules and other management tasks.
[0025] In the most basic example of a digital community, two user's systems, or peers, are both connected to the same network and agree to cooperate by sharing storage. For example, when both peers have free storage of 10 MB and each requires backup of 5 MB of storage, the two peers will each ‘lend’ 5 MB of backup storage to the community, and exchange digital assets requiring backup with one another. If peer A's device fails, peer A restores his digital assets from the copy residing on peer B's system.
[0026] In a more complex example, a community of several devices conforms to a common set of rules in order to achieve the same goals of reliable storage and backup since the number of devices is too great to enforce by mutual agreement between members, the community rules managing the storage and backup is preferably automated in conformance with the profiles of the peers weighted by the behavior of those peers. Such rule enforcement and application is discussed below with reference to FIG. 1 . FIG. 1 illustrates a storage community where three peers share storage. In the example of FIG. 1 , the peers are managed by a management node 18 , or governor node, that directs and controls storage of peer data on the community storage space (donated by peers). Such community rules dictate how peers will backup and retrieve storage from other peers and where such backup data is to be stored. For example, in one embodiment, the rules allow the community to answer the question whether a given peer should be granted backup storage on the community, how much backup storage to be granted, where the data should be stored, and what the requesting peer (client peer) must offer in exchange. The rules also control who may join the community, and who is dismissed from the community.
[0027] In the example of FIG. 1 , each peer 12 , 14 , 16 communicates data to the management server 18 . Such data includes initiation data ( FIG. 5 ), recovery instructions, and security data. Each client peer 12 , 14 , 16 also stores backup data on storage media associated with a service peer. Specifically, client peer A 12 stores data on service peers B 14 and C 16 , client peer B stores data on service peer A, and client peer C stores data on service peer A. In one instance of this example, peer A donates twice the data donated by peer B 14 and peer C 16 so as to allow peer A to increase data redundancy by storing the same data on two different service peers. In another instance of this example, peer A's storage requirements exceed those provided by either service peer B 14 or service peer C 16 alone and therefore peer A's data is divided between service peer B and service peer C.
[0028] Each peer is associated with a profile, which includes attributes such as the amount of free storage available, the amount of storage required for backup, frequency and size of backups, storage access time (which will primarily be a function of bandwidth and network performance on that peer), storage availability (for example, how often does that peer go to ‘sleep’), geographic location, hardware and software profile (including operating system and prevalent applications), and a network profile.
[0029] A reputation is assessed for each peer, which is characterized as the citizenship of that peer in the community. The citizenship of a peer is a function of their behavior and changes in profile over a period of time. For example, if a given peer reliably performs requested tasks of the community over a period of time, that peer's citizenship improves. If a given peer's profile changes (e.g. the device fails, new storage is added to the device, the operating system running on the device changes), the peer's citizenship is reassessed ( FIG. 7 ).
[0030] A peer's currency is the amount of storage the peer offers to the digital community weighted by citizenship, which in turn is a function of profile and behavior over time. The currency of a peer will dictate, in turn, what the community will offer the peer in exchange for currency. In one embodiment, reciprocity forms the basis of community rules. If a given peer requires 10 MB of backup storage, for example, that peer will be required to offer 10 MB of backup storage for another peer on the network. If a given peer requests redundant storage, that peer will be required to offer the commensurate amount of storage to other members of the community. Good citizens in the community (e.g. peers who maintain reliable systems and whose reputations for performing community requests for storage and retrieval improve over time) will have their storage requests performed on peers with like citizenship. Similarly, peers with poor citizenship will have their backup storage on peers with like citizenship. In other words, the reliability a peer provides will shape the reliability of where its data is stored.
[0031] In one embodiment, the governor and enforcement of the set of rules is by a centralized approach, where a governor node is used. In another embodiment, in a decentralized mode, software running on each peer agrees to conform to and enforce the community's rules. In this decentralized mode, the governor may maintain automation via agents that enforce conformance to community rules, or alternatively, users themselves who adopt and voluntarily enforce such community rules. In the former case of decentralized governor, whereby the agents running on peers enforce community rules and update weighted profiles of peers, peer currencies and addresses are broadcast to a defined community using an open set of protocols. In the centralized mode, agent roles are preferably reduced to monitoring and controlling member peers.
[0032] FIG. 2 illustrates logical elements of a peer system 12 in an embodiment of the invention. The peer system 12 includes an agent module 20 , which contributes to the community interaction of the pier. The logical elements also include a communication interface 22 , hardware (processor) 24 , data (applications and related data) 26 , and dedicated (donated) storage 28 . The agent 20 is an application associated with a particular community storage implementation, which provides peer management services. In one embodiment, the agent secures the data that is stored on the associated peer such that it can only be retrieved and accessed by the owner-client peer. The agent also facilitates data backup services for the peer's own data (which it is a client peer with respect of). Finally, the agent 20 monitors the peer's citizenship to control and restrict how the peer's data is stored. As discussed above, the hardware 24 , communication interface 22 , and data 26 associated with the peer are some of the attributes monitored by the community as part of the peer profile and citizenship.
[0033] The communication interface 22 corresponds to the hardware and software by which the peer is coupled to a network which is employed to communicate with other peers of the storage community. The processor 24 is the hardware used to execute processes on the peer system. The data 26 includes applications executing on the peer processor and associated application data (digital assets). As may be appreciated, the combination of hardware 24 , communication interface 22 , and data 26 , provides a system profile with a specific vulnerability as to data loss. Such vulnerability is referenced when determining which service peer is appropriate for an assessed client peer. As may be appreciated, it is advantageous to store client peer data on a service peer having different vulnerability profile so as to reduce the probability of a simultaneous system failure due to factors such as hardware failures, virus attack exploiting a software loophole, or network failures affecting specific network types protocols, or geographic regions.
[0034] FIG. 3 illustrated the logical elements of a central governor node 18 in an implementation of the invention. The governor node 18 facilitates community arbitration and management services which include determining where peer data is stored, assessing and storing citizenship profiles for peers, applying community rules, and managing data security services such as data encryption, key storage, and data retrieval. The logical elements associated with the illustrated governor node 18 include a security module 30 , a location module 34 , a profiles module 32 , and a rules module 36 .
[0035] The security module 30 provides data security functionality for the secure storage of data as well as for the protection of data from unauthorized access. The location module 34 stores data relating to service peers which store client peer data. The location module 34 interacts with an agent 20 of a client peer during the data recovery stage, when the client peer's data is to be retrieved from its stored location. As may be appreciated, by employing a location module 34 in the governor node, the example community maintains secrecy as to where client data is stored, thereby preventing malicious access to the data or destruction of data when malicious programs target a client or service peer. In another embodiment, the governor node employs and updates this location information to transparently migrate or duplicate data between service peers.
[0036] As discussed above with reference to the peer system logical elements, in some implementation of the invention, diverse communities are desirable and offer a higher degree of reliable backup and storage. For example, in such a community where there is substantial geographical diversity, those systems in a geographic region adversely affected by a natural disaster could rely on systems in other geographic regions. Similarly, if a particular computer virus successfully destroys certain software programs or systems, a diversity of software programs (e.g. operating systems, email clients, applications, etc.) would likely reduce the impact of the virus on the overall community, and hence enhance the probability of the community recovering data. Hence, the location module 34 of the governor node diversifies storage by reference to such factors so as to increase storage reliability for client peers.
[0037] The profiles module 32 stores peer profile data by reference to data attributes of peer citizenship. The profiles module 32 further updates peer profiles in response to profile events ( FIG. 7 ) or as a result of an explicit periodic query by the community. In one embodiment such query is used to ensure that the agent module has not been tampered with and has manipulated the data. In this embodiment, the community transmits a request to the agent for processing a known function with the stored data as input (e.g., hash function). Hence, the community is able to verify data integrity by application of such periodic queries. In one embodiment, the governor node measures profiles and citizenship by directly communication with a peer node such as by “pinging” the node to measure connectivity.
[0038] The profiles module 32 is employed by the location module to identify a proper service peer for a client peer requesting storage or when there is a change in peer currency (due to citizenship event) which requires moving client peer data to another service peer with a different service quality (currency requirement). The rules module 36 applies community rules relating to profile events, storage requests, and retrieval requests. The rules module 36 processes rules in response to requests from the location module and from the profiles module. The operation of the rules module 36 when processing an example rule is discussed below with reference to FIG. 6 .
[0039] FIG. 4 illustrates logical elements of an agent module 20 in a storage community implementation of the invention which is illustrated in FIG. 1 . The agent module 20 includes a profile element 40 , an event monitoring element 42 , a local storage element 44 , and a backup management element 46 . The local storage element 44 manages data protection for data stored by the peer as a service peer to prevent unauthorized access to, or copying of, stored data. The local storage element 44 also provides functions for facilitating storage of client peer data in accordance with encryption and location instructions from a governor node or an agent module 20 in a confederated implementation. Furthermore, when the data is required by the client peer, the local storage element facilitates the retrieval of data and transmission to the client peer without intervention from, or disruption of, the service peer system. The profile element 40 provides functions for monitoring the local peer system so as to asses citizenship. As may be appreciated, various methods may be employed by the profile element 40 to assess citizenship of the corresponding peer system. For example, in one method, a citizenship module resides alongside the agent (in the confederated model) or on the governor (in the federated model). The citizenship module initially establishes citizenship as a function of the currently proposed and assessed profile. the citizenship module then tracks and records behavior over time, e.g. changes in profile. The citizenship is then updated with any change in profile. Recent changes to profiles have a higher weighting than distant changes. For example, if a peer profile offers 10 MB of storage, 24 hours/7 days up time, and 1 MB/sec transfer time, an initial citizenship is granted reflective of that profile. If over time the citizenship module notices that up time is reduced to 20 hours/7 days, the citizenship score is reduced. If over time there is a disruption, for example the transfer time is only 500 KB/sec, the citizenship is reassessed. ( FIG. 7 ) The citizenship module also utilizes a behavior algorithm that weights different aspects of profile changes over time. In another embodiment, different profile attributes are also weighted differently. For example, in one embodiment, storage space and uptime are weighted higher than transfer performance.
[0040] The event monitor 42 facilitates responding to events of the peer system which may affect its currency (citizenship or profile) or affect the stored data. For example, if the local peer installs software which is known to be vulnerable to viruses, a profile event is observed and processed ( FIG. 7 ). The event monitor further responds to events affecting the stored data such as the user overwriting stored data or the storage media having malfunctioned or replaced.
[0041] The backup management module 46 provides functions for managing storage of the local peer data on a service peer. Such functions include communicating with a governor node (or another agent directly in the confederated model) to acquire a service peer and controlling the transmission of data to be stored on the assigned peer in accordance with scheduling and security parameters from the community.
[0042] In one embodiment, peer data confidentiality is protected by utilized encryption keys. There are three types of keys contemplated: a simple pin code, a physical hardware key, and keys generated and stored automatically by a governing service. In all three instances, the keys will not reside on the peers in the network, and will either be retained by the user (owner of the peer) or the governing service.
[0043] As discussed above, FIG. 1 illustrates a federated digital community implementation of the present invention. The illustrated embodiment includes a collection of multiple peers, and a centralized governor 18 . The centralized governor 18 preferably enforces community rules, establishes and maintains citizenship of each peer in the community, performs data addressing functions, manages encryption keys. FIG. 5 illustrates the enrollment process for a peer in the illustrated community of FIG. 1 . In one embodiment, the process of a peer petitioning a governor to join a community could be as simple as a user logging into a web site and presenting their address and profile. The peer first donates some storage to the community (Step 50 ). If acceptable to both parties (the governing service which administers this enrollment web site and the petitioning peer), the governor will distribute agent software to the peer. The peer profile is then observed by the agent during a profile buildup period (Step 52 ). At the conclusion of the profile buildup period, the peer is allocated currency in accordance with the donated storage and observed profile (Step 54 ). The peer then requests certain storage parameters for a desired storage Quality of Service (“QoS”) level. In one embodiment, the user select a level for each attribute of the desired storage node by “dialing” a desired level for each attribute (Step 56 ). Such “dialed” attributes include both profile related attributes as well as citizenship related attributes, such as “Uptime/Downtime.” The community (agent or governor node) verifies that the “dialed” parameters comply with community rules (Step 58 ) ( FIG. 6 ). If the requested parameters are within the rules, the community determined a storage plan for the peer data and facilitates execution of the storage plan by employing the community storage and any required governor node storage (Step 59 ).
[0044] FIG. 6 illustrates the operation of a rule verification module when confirming storage parameter selections by a client peer. The module determines the currency or credit level associated with the requested parameters (Step 60 ). In one embodiment such credit level is proportional to the requested storage, quality of storage, and requested behavior. The module then compares the requested credit level to the currency available to the client peer (Step 62 ). If the currency is lower than the requested credit level, the module provides a “fail—currency exceeded” message in response to the rule verification request (Step 64 ). If the currency is greater than the requested credit level, the module compares the requested storage to the storage donated by the peer (Step 66 ). If the donated storage is less than the requested storage, the module returns a message “fail—storage exceeded” in response to the rule verification request (Step 68 ). If the donated storage is greater than the requested storage, the module return a “rule pass” message (Step 69 ).
[0045] In one embodiment, agents running on peers are governed by the centralized governor. The agents store and retrieve data when requested by the governor. FIG. 7 illustrates the operation of the agent on a peer when detecting a reputation related event. The agent observes a profile event (step 70 ). The agent processes the event (Step 71 ) and then determines if reporting to the governor node is required (Step 72 ). As may be appreciated, not every event should be reported to the governor node. Events that can be resolved locally by the agent module are processed by the module (Step 73 ). Events that need governor node attention, such as loss of stored data, should be reported to the governor node (Step 74 ). If an event needs to be reported to the governor node, event processing at the governor node takes over (Step 75 ). If processing the profile event results in the peer currency falling below the currency required for storing its data at the current storage peer location (Step 76 ), the peer requested storage parameters should be “dialed” down to reduce currency use (Step 77 ). In one embodiment, the governor node automatically reduces the storage parameters so as to fall within the available currency. In another embodiment, the governor node interacts with the user to select reduced storage parameters which are within the available currency. Preferably such correction in storage currency is only performed on a limited periodic basis, so as to not overload the community and disrupt storage transaction. After new parameters are selected, the governor node initiates data transfers to implement the new peer relationships. In one embodiment, such data transfers employ local storage at the governor node as temporary buffer storage.
[0046] If the new peer profile does not pass the rules due to exceeded storage (Step 78 ), the governor node adjusts the storage available to the peer below the donated storage level (Step 79 ). The user is then contact by the community to select data for storage in accordance with the new storage level. If storage is not exceeded, the rule processing returns a “pass” indication (step 80 ). After data is selected for storage, the data is stored by the community by selecting an appropriate peer and moving data between the peers. As may be appreciated, the data is preferably compressed prior to storing on the service peer.
[0047] In one embodiment, the user further specifies an importance indication for identifiable data collections or specific data items (e.g., documents, photos, specific files, etc.). The community employs the importance designation to prioritize allocation of resources to the peer so as to provide a higher QoS for the more important data or so as to effectively employ newly excess community resources. In another embodiment, the agent module automatically prioritizes data by reference to factors such as access frequency and predetermined ranking by data type. In one embodiment, the agent module associated with the client system manages the allocation of resources to the client peer data by reference to the importance indication from the user. As may be appreciated, such importance indication is further employed when resources are removed from the community to determine which client data should be preserved and which should be discarded. In another embodiment, where excess resources are available, the community automatically increases the QoS with respect to certain peer data by allocating more than one resource to the peer data.
[0048] In yet another embodiment, a pay-to-store service is made available to client peers. In this embodiment, a client peer purchases storage credits which are then added to the client peer currency. The currency is then used to acquire storage resources of the community, which now include the purchased storage. As may be appreciated, the client peer data is not always stored on the pay-service storage server since such server may not always be the optimal location for storing the client data (e.g., same ISP, same city). Hence, the pay-to-store option is sometimes employed as a pay-to-donate option where payment is used to acquire storage that is then donated to the community in the name of the purchasing client peer.
[0049] As may be appreciated, in some community implementations, a peer may be banished from the community by the governor, at which point, any storage offered by that peer for backup by other members of the community is transferred to another member of the community. Examples of community rules for enforced banishment include cases where a peer does not conform to the community rule, a peer seeks to harm the community, a peer's citizenship degrades to the point where that peer cannot provide any useful services/storage to the community, etc.
[0050] In another embodiment, the storage community is facilitated as a confederated digital community where agents running on peers enforce community rules. In this embodiment there is no centralized governing service. Encryption keys are preferably maintained by users themselves, advantageously in hardware modules. Agents also store addressing information on a hardware module to prevent loss of addressing data on system failure. In such implementation a peer is invited to join community be an existing member. A client peer will broadcast their profile over a defined broadcast band for that network. To obtain storage, a client peer will broadcast a storage requests over defined broadcast band to members of their community. An available service peer will accept the broadcast and perform the requested service, at which point the client peer no longer broadcasts the request. Citizenship is gauged by self measuring agents and is stored on each peer. Agent modules on peers update the citizenship other peers based on events. Importantly, in a confederated digital community, the broadcast and distribution of peer profiles and addresses must be maintained only by members of the community. As such, this content is distributed in an encrypted form or channel to other peers, and peers may only join these communities by invitation from a member of the community. In some circumstances, the community rules may dictate that a majority of peers in the community must accept the petition for a new member (peer), etc.
[0051] In another embodiment, a storage community of the invention is implemented as a non-federated digital storage community. In this implementation, community rules are enforced by users and not agents or governing service. The operation of the community is the same as in the confederated case except responsibility of agent software running on the peer is delegated to the actual user.
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A digital community provides shared resources across a wide collection of users. Users donate resources to the community and in return are allowed to employ resources of the community. The digital community conforms to a set of rules, or community rules, so as to enhance cooperation between users and increase resource reliability. The resource sharing rules allow for efficient allocation and utilization of community resources. The rules refer to the hardware, software, and donor behavior associated with each resource of the community.
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RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/986,969, filed Jan. 7, 2011, and entitled “STORAGE PERFORMANCE OPTIMIZATION”, which is a divisional of U.S. patent application Ser. No. 12/122,579, filed May 16, 2008, and entitled “STORAGE PERFORMANCE OPTIMIZATION”, each of which is hereby incorporated by reference in its entirety into the present application.
FIELD OF THE INVENTION
The invention relates to management of data storage in a “database aware” distributed data environment where both local and remote storage systems are used simultaneously to fulfill IO requests.
BACKGROUND OF THE INVENTION
In traditional data warehousing and Data Mart (DM) environments, data is stored centrally on an External Storage System (ESS), such as, for example, a Storage Area Network (SAN), or locally. A single access point is typically configured in order to provide security (e.g., an ESS) or performance (e.g., access locally), but usually is not able to provide both economically. While an ESS can guarantee security, it may be prohibitively expensive to also provide performance in situations involving high data volumes or IO intensive applications. Conversely, local storage systems typically have high data throughput capabilities, but are not able to store high data volumes effectively or guarantee security without sacrificing storage capacity through excessive redundancy.
Parallel warehousing and DM environments present both opportunities and additional overhead in environments that rely on single storage configurations. Shared-nothing parallel database systems relying on local storage must develop sophisticated solutions for failover recovery (FR) and disaster recovery (DR). Such systems can double or quadruple storage requirements, hence reduce capacity on each server, which can lead to a proliferation of servers or reduced system capacity. Shared-storage parallel database systems (e.g., implementing an ESS) typically rely on centralized high-availability and security services, which reduces the FR and DR infrastructure complexity of parallel solutions, but at the cost of reduced data throughput. This may lead to inefficient use of the parallel systems, limit the expansion capabilities of the system, significantly reduce the system's ability to scale linearly to support increasing data volumes and application demands from expanded user requirements, and/or other drawbacks.
SUMMARY OF THE INVENTION
One aspect of the invention relates to systems and methods that seek to optimize (or at least enhance) data throughput in data warehousing environments by connecting multiple servers having local storages with a designated ESS, such as, for example, a SAN. According to another aspect of the invention, the systems and methods preserve a full reference copy of the data in a protected environment (e.g., on the ESS) that is fully available. According to another aspect of the invention, the systems and methods maximize (or at least significantly enhance) overall IO potential performance and reliability for efficient and reliable system resource utilization.
Other aspects and advantages of the invention include providing a reliable data environment in a mixed storage configuration, compensating and adjusting for differences in disk (transfer) speed between mixed storage components to sustain high throughput, supporting different disk sizes on server configurations, supporting high performance FR and DR in a mixed storage configuration, supporting dynamic reprovisioning as servers are added to and removed from the system configuration and supporting database clustering in which multiple servers are partitioned within the system to support separate databases, applications or user groups, and/or other enhancements. Servers within the data warehousing environment may be managed in an autonomous, or semi-autonomous, manner, thereby alleviating the need for a sophisticated central management system.
According to some embodiments, a system may include one or more of an ESS, one or more servers, local storage associated with individual ones of the servers, one or more clients, and/or other components. The ESS may hold an entire copy of the database. The local storage at individual ones of the servers may hold a portion of the database. A given server may manage the storage of data within the corresponding local storage, and may manage the retrieval of data from the ESS and/or the corresponding local storage. A given client may be operatively linked with a server, and may provide an interface between the database and one or more users and/or administrators.
The ESS may hold a copy of the entire database. This copy may be kept current in real-time, or near real-time. As such, the copy of the database held by the ESS may be used as a full reference copy for FR or DR on portions of the database stored within the local storage of individual servers. Since the copy of the ESS is kept continuously (or substantially so) current, “snapshots” of the database may be captured without temporarily isolating the ESS artificially from the servers to provide a quiescent copy of the database. By virtue of the centralized nature of the ESS, the database copy may be maintained with relatively high security and/or high availability (e.g., due to standard replication and striping policies). In some implementations, the ESS may organize the data stored therein such that data that is accessed more frequently by the servers (e.g., data blocks not stored within the local storages) is stored in such a manner that it can be accessed efficiently (e.g., for sequential read access). In some instances, the ESS may provide a backup copy of portions of the database that are stored locally at the servers.
The local storages corresponding to individual ones of the servers store part of the database contained within the ESS. The storage system architecture and/or configuration of the individual local storages is not specified by the overall system. For example, separate local storages may be provided by different types of storage devices and/or such storage devices may have different configurations. In some implementations, a given local storage may be partitioned to provide storage for other applications as well as the system described herein.
The servers may form a network of server computer nodes, where one or more leader nodes communicate with the client to acquire queries and deliver data for further processing, such as display, and manages the processing of queries by a plurality of compute node servers. Individual servers process queries in parallel fashion by reading data simultaneously from local storage and the ESS to enhance I/O performance and throughput. The proportions of the data read from local storage and the ESS, respectively, may be a function of (i) data throughput between a given server and the corresponding local storage, and (ii) data throughput between the ESS and the given server. In some implementations, the proportions of the data read out from the separate sources may be determined according to a goal of completing the data read out from the local storage and the data read out from the ESS at approximately the same time. Similarly, the given server may adjust, in an ongoing manner, the portion of the database that is stored in the corresponding local storage in accordance with the relative data throughputs between the server and the local storage and between the server and the ESS (e.g., where the throughput between the server and the local storage is relatively high compared to the throughput between the server and the ESS, the portion of the database stored on the local storage may be adjusted to be relatively large). In some implementations, the individual servers may include one or more of a database engine, a distributed data manager, a I/O system, and/or other components.
The clients may operatively connect to the servers, and may generate database queries that are routed to the servers. Results of the queries (generated by processing on the server) may be sent to the client for disposition and display processing.
According to various embodiments, data may be loaded from an external data source (e.g., via a client) to the database. A method of loading such data to the database may include receiving the data from the external data source, organizing the received data (e.g., into data blocks), writing the received data into the database held in the ESS, and/or writing portions of the received data into the individual local storages by the individual servers.
In some embodiments, queries received from the client may be processed by the servers. A method of receiving and processing such a query may include receiving a query from a client, distributing the query amongst the servers for processing, at individual servers, determining the amount of data that should be read from local storage and the amount that should be read from the ESS, reading the data out of local storage and the ESS, processing the received data, and/or returning results of the processing to the client. Where the processing of the received data involves the materialization of intermediate data, on a given one of the servers such data may be stored in local storage and/or stored in the ESS based on user configurable settings. In some implementations, the user configurable settings may depend on one or more criteria, such as, for example, capacity utilization, throughput balancing, and/or storage balancing.
In some embodiments, data within the database may be updated and/or deleted (e.g., as data is deleted and/or updated in an external data source). A method for reflecting such changes in the data may include receiving the update and/or deletion, updating and/or deleting the corresponding data (e.g., rows, elements, etc.) within the database copy stored in the ESS, updating the database portions stored by the various local storages corresponding to the servers, and/or adjusting the storage of data within the individual local storages to maintain the balance between the individual local storages and the ESS. In some implementations, a vacuum command may be initiated on one or more of the servers that vacuums the corresponding local storages to remove discontinuities within the portions of the database stored within the local storages that are caused by the updating and/or deleting of data from the stored database portions.
In some embodiments, snapshots of the database may be captured from the ESS. A snapshot may include an image of the database that can be used to restore the database to its current state at a future time. A method of capturing a snapshot of the database may include, monitoring a passage of time since the previous snapshot, if the amount of time since the previous snapshot has breached a predetermined threshold, monitoring the database to determine whether a snapshot can be performed, and performing the snapshot. Determining whether a snapshot can be performed may include determining whether any queries are currently being executed on the database and/or determining whether any queries being executed update the persistent data within the database. This may enhance the capture of snapshots with respect to system in which the database must isolated from queries, updated from temporary data storage, and then imaged to capture a snapshot because snapshots can be captured during ongoing operations at convenient intervals (e.g., when no queries that update the data are be performed).
In some implementations, snapshots of the database may be captured by keeping multiple tables of contents of the blocklist of the database. The table of contents may include the storage address of the data blocks and possibly other block attributes. The table of contents operates in such a manner that when a snapshot is requested, the current table of contents is saved and becomes the snapshot table of contents. A new table of contents is created that initially contains the same information as the snapshot table of contents, but any changes to the database are make made by creating new blocks which are only referenced by the new table of contents. In this embodiment, any number of tables of contents may be created, one for each snapshot. To achieve consistency of the database snapshot across all servers in a multi-server database system, the snapshot may be performed on all servers with no intervening block data writes during the interval in time from the snapshot of the first server's table of content until the snapshot is complete for the last server's table of contents.
In some implementations, snapshots of the database may be captured by utilizing a number of tables of contents where each table of contents includes the size of each data block in addition to the storage address of the block and possibly other block attributes. In such implementations, a database transaction, such as, for example, SQL commit, is performed by writing an additional table of contents that includes the new block sizes. The older tables of content refer to the database state, pre-commit, because they contain the block sizes as they existed before any writes by the transaction being committed. The newer table of contents may include blocks that have been created by the transaction and may exclude blocks that have been abandoned by the transaction. In this embodiment, a snapshot to the ESS may be performed at any time during database operation except the short interval starting from the first server's creation of the table of contents to the last server's completion of creation of its table of contents.
These and other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system configured to provide a database, in accordance with one or more embodiments of the invention.
FIG. 2 illustrates a server, according to one or more embodiments of the invention.
FIG. 3 illustrates a method of loading data (e.g., from an external data source) to the database, in accordance with one or more embodiments of the invention.
FIG. 4 illustrates a method 40 of receiving and processing a query on a database, according to one or more embodiments of the invention.
FIG. 5 illustrates a method 54 of deleting and/or updating data within the database, in accordance with one or more embodiments of the invention.
FIG. 6 illustrates a method 64 capturing a snapshot of a database, according to one or more embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a system 10 configured to provide a database, in accordance with one or more implementations of the invention. System 10 may enhance access of the database by increasing overall data throughput of system 10 in processing queries on the database. System 10 may provide enhancements in one or more of security, FR, DR, and/or other aspects of the database at least in part through a mixed storage configuration. As can be seen in FIG. 1 , in some implementations, system 10 may include one or more of a client 12 , an ESS 14 , one or more servers 16 , local storage 18 corresponding to individual ones of servers 16 , and/or other components.
Clients 12 may be operatively connected to servers 16 , and may generate database queries that are routed to servers 16 . Results of the queries (generated by processing on the server) may be sent to the querying client 16 for disposition and display processing. In some implementations, client 12 may be provided on a computing platform, such as, for example, a desktop computer, a laptop computer, a handheld computer, a mobile telephone, a personal digital assistant, and/or other computing platforms. Client 12 may provide an interface for users to interact with the database.
ESS 14 may include an external storage system capable of holding a copy of the entire database. For example, in some implementations, ESS 14 may include a SAN. The copy of the database held on ESS 14 may be kept current in real-time, or near real-time. As such, the copy of the database held by ESS 14 may be used as a full reference copy for FR or DR on portions of the database stored within the local storages 18 of individual servers 16 . Since the copy of the database held by ESS 14 is kept continuously (or substantially so) current, “snapshots” of the database may be taken by an data imaging module 20 without temporarily isolating ESS 14 from servers 16 in order to ensure that the database will be quiescent. By virtue of the centralized nature of ESS 14 , the database copy may be maintained thereon with relatively high security and/or high availability (e.g., due to standard replication and striping policies). In some implementations, ESS 14 may organize the data stored therein such that data accessed more frequently by servers 16 in the manner discussed below (e.g., data blocks not stored within the local storages) may be stored so that it can be accessed more efficiently than data that is requested by servers 16 with less frequency (e.g., for sequential read access). In some instances, the copy of the database held on ESS 14 may not only provide for access by server 16 to data within the database to process queries, but may also provide a backup copy for FR and/or DR on portions of the database stored on local storages 18 locally to servers 16 . As such, the commitment of data to the database copy held on ESS 14 may constitute commitment of the data and backup of the data in a single operation.
As has been mentioned above, data imaging module 20 may operate to capture snapshots of the database. A snapshot may include a data image of the database that can be used to restore the database to its current state at a future time. Data imaging module 20 may monitor one or more parameters to determine if a snapshot should be captured. In some instances, the one or more parameters may include one or more of an amount of time, a number of querying operations performed on the database, an amount of information added, deleted, and/or updated within the database, and/or other parameters related to the obsolescence of the previous snapshot. For example, if the parameter is an amount of time, data imaging module may determine if an amount of time that has passed since the previous snapshot has breached a predetermined threshold. This predetermined threshold may be configurable (e.g., by a system administrator).
If the threshold of the parameter (e.g., the amount of time since the previous snapshot, etc.) has been breached, data imaging module 20 may monitor the database to determine whether a snapshot can be performed. Determining whether a snapshot can be performed may include determining whether any queries are currently being executed on the database and/or determining whether any queries being executed update the persistent data within the copy of the database stored in ESS 14 . Upon determining that a snapshot can be performed data imaging module 20 may capture a snapshot of ESS 14 without manually isolating ESS 14 from the rest of system 10 . This may enhance the capture of snapshots with respect to a system in which the database must be manually isolated from queries, updated from temporary data storage, and then imaged to capture a snapshot because snapshots can be captured by data imaging module 20 during ongoing operations at convenient intervals (e.g., when no queries that update the data are be performed).
In some implementations, snapshots of the database may be captured by keeping multiple tables of contents of the blocklist of the database. The table of contents may include the storage address of the data blocks and possibly other block attributes. The table of contents operates in such a manner that when a snapshot is requested, the current table of contents is saved and becomes the snapshot table of contents. A new table of contents is created that initially contains the same information as the snapshot table of contents, but any changes to the database are make made by creating new blocks which are only referenced by the new table of contents. In such implementations, any number of tables of contents may be created, one for each snapshot. To achieve consistency of the database snapshot across all servers 16 in system 10 , the snapshot may be performed on substantially all servers 16 with no intervening block data writes during the interval in time from the snapshot of the first server's table of content until the snapshot is complete for the last server's table of contents.
In some implementations, snapshots of the database may be captured by utilizing a number of tables of contents where each table of contents includes the size of each data block in addition to the storage address of the block and possibly other block attributes. In such implementations, a database transaction, such as an SQL commit, is performed by writing an additional table of contents that includes the new block sizes. The older tables of content refer to the database state, pre-commit, because they contain the block sizes as they existed before any writes by the transaction being committed. The newer table of contents may include blocks that have been created by the transaction and may exclude blocks that have been abandoned by the transaction. In this embodiment, a snapshot to the ESS may be performed at any time during database operation except the short interval starting from the first server's creation of the table of contents to the last server's completion of creation of its table of contents.
Servers 16 may provide a network of processing nodes, where one or more of servers 16 may function as leader nodes that communicate with client 12 to acquire queries and/or deliver data for further processing on client 12 . A leader node may further manage one or more of the other servers 16 acting as computing nodes to process a queries acquired by the leader node.
Local storages 18 corresponding to individual ones of servers 16 store part of the database copy contained within ESS 14 . The architecture and/or configuration of the individual local storages 18 is not specified by system 10 . For example, separate local storages 18 may be provided by different types of storage devices and/or such storage devices may have different configurations. In some implementations, a given local storage 18 may be partitioned to provide storage for other applications as well as the system described herein. For example, a given local storage 18 may use RAID5 for local performance and disk failover, may use RAID1 for local redundancy, etc.
The architecture and/or functionality of system 10 may enable each of servers 16 and the corresponding local storage 18 to function as an autonomous (or semi-autonomous) unit. For example, various aspects of the storage of a portion of the database on local storage 18 may be accomplished by server 16 without the need of organization/management from some centralized manager (e.g., provided at or with ESS 14 ).
FIG. 2 illustrates, with more detail than is shown in FIG. 1 , a configuration of server 16 and local storage 18 within system 10 , in accordance with one or more embodiments of the invention. As can be seen in FIG. 2 , server 16 may include one or more of a database engine 22 , a distributed data manager 24 , an I/O system 26 , and/or other components. One or more of the components may be provided by modules being executed on one or more processors. A processor may include one or more of a central processing unit, a digital circuit, an analog circuit, a state machine, a field-programmable gate array, and/or other processors. One or more of database engine 22 , distributed data manager 24 , and/or I/O system 26 may be implemented in hardware, software, firmware, and/or some combination of hardware, software, and/or firmware.
In some implementations, database engine 22 may include an application capable of managing communication with client 12 (e.g., receiving queries, outputting results, etc.), receiving data from data sources to be written to the database, receiving deletions and/or updates to the data contained within the database, managing queries received from client 12 , obtaining data from the database to process the data in accordance with queries from client 12 , processing data from the database in accordance with queries received from client 12 , and/or other tasks with respect to the database.
According to various implementations, distributed data manager 24 may manage transactions between database engine 22 and the database such that the parallel storage of the database between local storage 18 and ESS 14 may be transparent to database engine 22 . In other words, the logical view of the representation of data within the database from the point of view of database engine 22 (e.g., LUN, block format, block layout, file system/raw device, etc.) may be the same for data stored on both local storage 18 and ESS 14 . As such, physical knowledge of where data is actually stored (within local storage 18 and/or ESS 14 ) may be maintained by distributed data manager 24 . Further, transactions between database engine 22 and the database through I/O system 26 may be routed through distributed data manager 24 to ensure that data is received from and/or written to the appropriate storage locations.
If database engine 22 generates a request to receive data from the database, distributed data manager 24 may map the request to portions of the requested data stored in each of local storage 18 and ESS 14 so that separate portions of the data are read out from local storage 18 and ESS 14 in parallel fashion, thereby enhancing I/O performance and throughput. The proportions of the data portions read from local storage and ESS 14 , respectively, may be a function of (i) data throughput between server 16 and local storage 18 , and (ii) data throughput between ESS 14 and server 16 . In some implementations, the proportions of the data portions read out from the separate sources may be determined according to a goal of completing the data read out from local storage 18 and the data read out from ESS 14 at approximately the same time. For example, in a configuration where overall data throughput between local storage 18 and server 16 is 800 MB/s, and throughput between ESS 14 and server 16 is 400 MB/s, distributed data manager 24 may map a request for data from the database to a request from local storage for ⅔ of the requested data and a separate request from ESS 14 for the remaining ⅓ of the requested data.
Where processing a request causes database engine 22 to generate intermediate data, distributed data manager 24 may manage the storage of the intermediate data to one or both of ESS 14 and/or local storage 18 . The determination as to whether the intermediate data should be written to ESS 14 , local storage 18 , or some combination of ESS 14 and local storage 18 (and the proportions that should go to each of ESS 14 and local storage 18 ) may be based on capacity, utilization, throughput, and/or other parameters of ESS 14 and/or local storage 18 .
In some implementations, distributed data manager 24 may control the portion of the database that is written to local storage 18 . The proportion of the database included in this portion may be a function of one or more of available storage space in local storage 18 (e.g., larger available storage may receive a larger proportion of the database), data throughput between local storage 18 and server 16 (e.g., the faster data can be read out from local storage 18 to server 16 , the larger the proportion saved to local storage 18 may be), ESS 14 utilization (e.g., the heavier utilization of ESS 14 , the larger the proportion saved to local storage 18 may be), and/or other parameters that impact the storage of information to local storage 18 and/or the communication of information between server 16 and local storage 18 . For example, if throughput between local storage 18 and server 16 is twice as fast as throughput between ESS 14 and server 16 (as was the case in the exemplary configuration described above), distributed data manager 24 may cause ⅔ of the database to be stored in local storage 18 . Of course, this distribution may further be impacted by one or more other parameters (e.g., those enumerated in this paragraph).
Distributed data manager 24 may control which data within the database will be included in the portion of the database stored to local storage 18 . The determination as to which data should be stored to local storage may be based on parameters related to the data such as, for example, whether data is persistent, temporary, intermediate, and/or other parameters. The determination may be related to one or more system parameters, such as, for example, capacity, utilization, throughput, and/or other parameters of ESS 14 and/or local storage 18 .
Distributed data manager 24 may control the manner in which data from the database is physically stored on local storage 18 . For example, distributed data manager 24 may ensure that data is stored on the outer tracks of disks forming local storage 18 (e.g., to facilitate read-out). In some instances, distributed data manager may ensure that the data from the database is balanced between the disks forming local storage 18 to alleviate “hot spots” and/or other adverse impacts of unbalanced storage.
In certain implementations, distributed data manager 24 may perform periodic audits of one or more system parameters that may impact the amount of data that should be included within the portion of the database stored to local storage 18 . These system parameters may include one or more of data throughput between server 16 and local storage 18 , data throughput between server 16 and ESS 14 , ESS 14 utilization, local storage 18 utilization, storage location on local storage 18 , and/or other system parameters. Upon performing such an audit, distributed data manager 24 may migrate data between local storage 18 and ESS 14 and/or may relocate the physical storage of data on local storage 18 in order to compensate for changes in the system parameters audited (e.g., where the throughput between 16 server and local storage 18 decreases, the portion of the database stored within local storage is decreased).
When data is entered to system 10 (e.g., through an external data source, through client 12 , etc.), distributed data manager 24 may write the data to the database, ensuring that it is stored appropriately at ESS 14 and/or local storage 18 . Upon receiving data, distributed data manager 24 may organize the data into blocks. A block of data may form the smallest unit of physical storage allocated to local storage 18 . By way of non-limiting example, a block of data may comprise columnar values of the database, row values of the database, and/or other blocks of data from the database. Blocks of data may hold data from the database in raw or compressed form. The blocks may then be directed by distributed data manager 24 , through I/O system 26 , to ESS 14 to be written to the database. Distributed data manager 24 may determine whether some or all of the new blocks should be included within the portion of the database stored on local storage 18 to maintain the appropriate proportion of the database on local storage 18 , and may direct the appropriate blocks, through I/O system 26 , to local storage 18 .
Similarly, if data is deleted from and/or updated in system 10 , (e.g., through an external data source, through client 12 , etc.), distributed data manager 24 may map the deletions and/or updated data to the appropriate locations on ESS 14 and/or local storage 18 . Further, distributed data manager 24 may determine whether the changes to the data caused by the deletions and/or updates have given rise to a need for the portion of the database stored within local storage 18 to be adjusted to maintain the appropriate proportion between the portion of the database stored on local storage 18 and the database as a whole.
As should be appreciated from the foregoing, each server 16 of system 10 includes its own distributed data manager 24 capable of managing the storage of data on local storage 18 , accessing data from the database, handling deletions and/or updates to the database, and/or performing other tasks related to the database in an autonomous (or semi-autonomous) manner. Further, although the processing of the database in accordance with a query from client 12 may be performed in cooperation by a plurality of servers 16 , each server 16 may manage its own distinct subset of the requisite processing in an autonomous (or semi-autonomous) manner. This may present an advantage over conventional systems utilizing centralized storage of the database, such as a SAN, in that the operation of individual servers 16 does not rely on a centralized management processor to facilitate database operations on the server level.
FIG. 3 illustrates a method 28 of loading data (e.g., from an external data source) to the database. Although the operations of method 28 are discussed below with respect to the components of system 10 described above and illustrated in FIGS. 1 and 2 , it should be appreciated that this is for illustrative purposes only, and that method 28 may be implemented with alternative components and/or systems without departing from the scope of this disclosure. Further, the operations of method 28 presented below are intended to be illustrative. In some embodiments, method 28 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 28 are illustrated in FIG. 3 and described below is not intended to be limiting.
Method 28 includes an operation 30 , at which data may be received from an external data source. In some embodiments, operation 30 may be performed by a database engine of a database server similar to, or the same as, database engine 22 of server 16 , illustrated in FIG. 2 and described above.
At an operation 32 , the data received at operation 30 may be organized into blocks for storage in the database. In some embodiments, operation 30 may be performed by a distributed data manager of a database server similar to distributed data manager 24 , illustrated in FIG. 2 and described above.
At an operation 34 , the data blocks formed at operation 32 may be written to an ESS (e.g., such as ESS 14 , shown in FIGS. 1 and 2 and described above). In some embodiments, operation 32 may be performed by the distributed data manager.
At an operation 36 , a determination is made as to whether any of the newly added data should be stored locally to the database server. This determination may be made to maintain a portion of the database on storage local to the server (e.g., local storage 18 , illustrated in FIGS. 1 and 2 , and described above) with a predetermined proportion to the database as a whole. The distributed data manager of the database server may make this determination based on one or more of the parameters discussed above with respect to distributed data manager 24 (illustrated in FIG. 2 ).
At an operation 38 , the portion of the newly added data, if any, is written to storage that is local to the server. Operation 38 may be performed by the distributed data manager.
FIG. 4 illustrates a method 40 of receiving and processing a query on a database. Although the operations of method 40 are discussed below with respect to the components of system 10 described above and illustrated in FIGS. 1 and 2 , it should be appreciated that this is for illustrative purposes only, and that method 40 may be implemented with alternative components and/or systems without departing from the scope of this disclosure. Further, the operations of method 40 presented below are intended to be illustrative. In some embodiments, method 40 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 40 are illustrated in FIG. 4 and described below is not intended to be limiting.
At an operation 42 , a query may be received. The query may be received from a database client, such as client 12 , shown in FIGS. 1 and 2 and described above. In some embodiments, operation 42 may be performed by a database engine of a database server that is similar to, or the same as, database engine 22 of server 16 , illustrated in FIGS. 1 and 2 and described above.
At an operation 44 , a determination may be made as to which data in the database should be retrieved in order to process the query received at operation 42 , and a request for this data may be generated. In some embodiments of the invention, operation 44 may be performed by the database engine.
At an operation 46 , the request generated at operation 44 may be translated to retrieve separate portions of the requested data in parallel from an ESS (e.g., ESS 14 shown in FIGS. 1 and 2 and described above) and storage that is local to the server (e.g., local storage 18 shown in FIGS. 1 and 2 and described above). The portions of the requested data may be determined based on the relative throughputs of the ESS and the local storage to the server with the intention that both of the retrievals will take the approximately the same amount of time. In some embodiments, operation 46 may be performed by a distributed data manager of the server that is the same as or similar to distributed data manager 24 shown in FIG. 2 and described above.
At an operation 48 , the separate data portions determined at operation 46 may be received by the database server, and at an operation 50 , the received data may be processed in accordance with the query received at operation 42 . In some instances, the processing of the received data involves the materialization of intermediate data. Such intermediate data may be stored in local storage and/or stored in the ESS based on user configurable settings. In some implementations, the user configurable settings may depend on one or more criteria, such as, for example, capacity utilization, throughput balancing, and/or storage balancing. In some embodiments, the processing of data at operation 50 may be performed by the database engine, while the storage and/or retrieval of intermediate data may be managed by the distributed data manager.
At an operation 52 , the results of the processing performed at operation 52 may be returned to the querying client. In some embodiments, operation 52 may be performed by the database engine.
FIG. 5 illustrates a method 54 of deleting and/or updating data within the database. Although the operations of method 54 are discussed below with respect to the components of system 10 described above and illustrated in FIGS. 1 and 2 , it should be appreciated that this is for illustrative purposes only, and that method 54 may be implemented with alternative components and/or systems without departing from the scope of this disclosure. Further, the operations of method 54 presented below are intended to be illustrative. In some embodiments, method 54 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 54 are illustrated in FIG. 5 and described below is not intended to be limiting.
At an operation 56 , an update and/or deletion to data within the database may be received and a command to update and/or delete the appropriate data may be generated. In some embodiments, operation 56 may be performed by a database engine of a database server that is the same as, or similar to, database engine 22 shown in FIG. 2 and described above.
At an operation 58 , the update and/or deletion to data within the database is mapped to the appropriate data stored within an ESS (e.g., ESS 14 shown in FIGS. 1 and 2 and described above) that holds the database. In some instances, the data may further be held within a portion of the database stored locally by the database server (e.g., within local storage 18 shown in FIGS. 1 and 2 and described above). In these instances, the update and/or deletion may be mapped to the appropriate data within the local storage. In some embodiments, operation 58 may be performed by a distributed data manager of the server that is the same as or similar to distributed data manager 24 shown in FIG. 2 and described above.
At an operation 60 , the appropriate data stored on the ESS is updated and/or deleted, and at an operation 62 , the appropriate data stored on the local server is updated and/or deleted. At an operation 63 , the proportion of the portion of the database stored on the local storage to the database as a whole is adjusted to account for the update and/or deletion of data performed at operations 60 and 62 . In some embodiments, operation 63 may be performed by the distributed data manager to maintain the appropriate balance between the portion of the database stored on the local storage and the database as a whole in the manner described above with respect to distributed data manager 24 .
FIG. 6 illustrates a method 64 capturing a snapshot of a database without manually isolating the database from queries to update the database and/or create an artificially quiescent database. Although the operations of method 64 are discussed below with respect to the components of system 10 described above and illustrated in FIGS. 1 and 2 , it should be appreciated that this is for illustrative purposes only, and that method 64 may be implemented with alternative components and/or systems without departing from the scope of this disclosure. Further, the operations of method 64 presented below are intended to be illustrative. In some embodiments, method 64 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 64 are illustrated in FIG. 6 and described below is not intended to be limiting.
At an operation 66 , a threshold of one or more parameters related to the obsolescence of a previous snapshot is determined. The threshold may be determined based on one or more of a user configuration, a system parameter, a hard-coded (e.g., permanent) threshold, and/or otherwise determined. In some embodiments, operation 66 may be determined by a data imaging module that is the same as, or similar to, data imaging module 20 shown in FIG. 1 and described above.
At an operation 68 , the one or more parameters related to the obsolescence of the previous snapshot are monitored. In some embodiments, operation 68 may be performed by the data imaging module.
At an operation 70 , a determination may be made as to whether the one or more monitored parameters have breached the threshold. In some embodiments, operation 70 may be performed by the data imaging module. If the one or more parameters have not breached the threshold, then method 64 may return to operation 68 . If the one or more parameters have breached the threshold, then method 64 may proceed to an operation 72 .
At operation 72 , a determination may be made as to whether a snapshot may be captured. The determination of operation 72 may include, for example, a determination as to whether any queries are currently being processed on the database, a determination as to whether any queries being executed update persistent data in the database, and/or other determination related to whether the database is sufficiently quiescent for a snapshot to be taken. In some embodiments, operation 72 may be performed by the data imaging module.
At an operation 74 , a snapshot of the database may be obtained. The snapshot may include an image of the database that can be used to restore the database to its current state at a future time. In some embodiments, operation 74 may be performed by the data imaging module.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
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A system and method for enhancing data throughput in data warehousing environments by connecting multiple servers having local storages with designated external storage systems, such as, for example, those provided by SANS. The system and method may preserve a full reference copy of the data in a protected environment (e.g., on the external storage system) that is fully available. The system and method may enhance overall I/O potential performance and reliability for efficient and reliable system resource utilization.
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This application claims benefit of U.S. provisional application Ser. No. 60/777,104 filed Feb. 27, 2006, the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus and process for using corona discharge to deposit colloidally suspended molecules onto substrate surfaces. The method is applicable to deposition of organic and inorganic compounds, particularly to proteins and related biological compounds of interest onto selected substrates with little or no loss of native structure or activity.
2. Description of Background Art
There is increasing interest in the immobilization of biologically active substances onto various substrates without significant alteration of function or desired activity. Surfaces coated with antibiotics, for example, are typically prepared by dipping or paint processes, which often result in poor adhesion, incomplete surface wetting or poor adhesion.
Ionic plasma deposition (IPD) methods have been extensively developed and used in coating processes, predominately with the objective of producing highly adhesive coatings and customized surface characteristics. Attention has recently focused on preparing coated surfaces that are biocompatible, such as those suitable for medical implants where the coatings enhance cell adhesion or where antimicrobial coatings are important in avoiding potential sepsis after surgery.
Corona discharge is a well-known phenomenon which has long been observed in nature and traditionally used in a number of commercial and industrial processes. It is currently used in ozone production, control of surface generated electrical charges and in photocopying. Electric corona discharge has also been used to modify surfaces, particularly for plastic articles to improve surface characteristics, as described in U.S. Pat. No. 3,274,089. An electrostatic coating process involving a corona discharge of a liquid or powdered material is described as a coating method, U.S. Pat. No. 4,520,754.
A corona is generated when the potential gradient is large enough at a point in the fluid to cause ionization of the fluid so that it becomes conductive. If a charged object has a sharp point, the air around that point will be at a much higher gradient than elsewhere. Air near an electrode can become ionized (partially conductive), while regions more distant do not. When the air near the point becomes conductive, it has the effect of increasing the apparent size of the conductor. Since the new conductive region is less sharp, the ionization may not extend past the local region. Outside the region of ionization and conductivity, the charged particles slowly find their way to an oppositely charged object and are neutralized.
Corona discharge usually involves two asymmetric electrodes; one highly curved, e.g., a needle tip or a small diameter wire, and one of low curvature, e.g., a plate, or a ground. The high curvature ensures a high potential around the electrode, providing for the generation of a plasma. If the geometry and gradient are such that the ionized region continues to grow instead of stopping at a certain radius, a completely conductive path may be formed, resulting in a momentary spark or a continuous arc.
Coronas may be positive or negative. This is determined by the polarity of the voltage on the highly-curved electrode. If the curved electrode is positive with respect to the flat electrode a positive corona exists; otherwise the corona is negative. The physics of positive and negative coronas are strikingly different. This asymmetry is a result of the great difference in mass between electrons and positively charged ions, with only the electron having the ability to undergo a significant degree of ionizing inelastic collision at ordinary temperatures and pressures.
Corona discharge systems have been used to activate chemical compounds, generally to deposit polymers and polymerizable monomers formed within a corona discharge onto surfaces as protective coatings; as described in U.S. Pat. No. 3,415,683. A corona discharge reactor for chemically activating constituents of a gas stream; e.g, sulfur and nitrogen oxides and mercury vapor, is described in U.S. Pat. No. 5,733,360. The reactor is designed to pulse generate a corona by applying high voltages pulses for up to 100 nanoseconds to a plurality of corona discharge electrodes.
WO 2006/046003 describes several methods for coating substrates involving use of a plasma, including use of low pressure pulsed plasma to introduce monomers or monomers in combination with free radical initiators to initiate polymerization on a suitable substrate. An atmospheric pressure diffuse dielectric barrier discharge assembly is used into which an atomized liquid containing the monomers is introduced so that a coating material is formed from atomized drops of from 10 to 100 μm. An atmospheric pressure glow discharge plasma generating apparatus using radiofrequency energized electrodes is described in WO 03/084682.
A plasma coating apparatus and method are described in WO 02/28548. Liquid or solid atomized coating forming materials are introduced into a plasma discharge at atmospheric pressure and are useful for organic coatings such as polyacrylic acid or perfluoro compounds in addition to silicon-containing monomers.
Corona effects are not always considered beneficial and may in fact cause arcing, or the breakdown of the corona. In addition to this breakdown, the corona effect may be too strong to successfully only singly charge a complex molecule. When molecules ionize at a higher level, they may break apart and lose structural and functional properties.
One disadvantage of depositing materials generated in plasmas from liquid solutions is that any solvent present is typically deposited along with the intended material, creating unintended structures. For most processes where corona discharge can occur during plasma generation, efforts are usually taken to reduce the corona effect rather then using this effect as a deposition technique.
Deficiencies in the Art
The loss of functional and/or physical properties of plasma surface deposited organic molecules points to the need to develop methods of maintaining desirable biological activities of immobilized materials. Attempts to engineer biological coatings on a range of substrates, such as plastics, metals, polymers, and ceramics have met with limited success and generally have failed to deposit biologically active agents on surfaces without compromising desired activity.
SUMMARY OF THE INVENTION
The present invention relates to a molecular plasma deposition method for non-destructively coating biological agents on substrate surfaces. The method employs a modified IPD apparatus utilizing electric fields and vacuum to lay down a biological coating on virtually any conductive surface, and many non-conductive surfaces. A corona plasma molecular discharge is generated from a highly charged conductive tip. The method is applicable to deposition of a wide range of organic and inorganic materials, which are dispersed as solutions or suspensions from the conductive tip.
There are several features of the described method that differ from conventional uses of either corona discharges or ionic plasma depositions. The method employs solutions or suspensions of the materials to be deposited. This allows a wide range of organic as well as inorganic materials to be used, including elements and compounds. The liquids are atomized through a small pointed orifice maintained at a high voltage so that an ionized plasma is dispensed from the orifice. In a subsequent step of the method, the ionized plasma is directed into an evacuated chamber where an oppositely biased substrate is located, causing the material to be deposited where it becomes bonded to the surface of the substrate.
An important feature of the method is the deposition of biologically active agents onto a surface with little or no alteration of structure or functional characteristics. The method is equally applicable to inorganic materials, elements and select compositions, which are not otherwise amenable to coating processes. Due in part to the wide range of materials that can be deposited by this method, the ability to modify or bio-engineer different surfaces is significantly expanded.
The known characteristics of the corona effect under atmospheric conditions and the advantages of ionic plasma deposition (IPD) methods in coating processes have been used to develop a novel corona plasma deposition process and coating method. An important aspect of the invention is the ability to use a corona generated from a liquid or colloidal composition to deposit a coating consisting of only the desired component, without the solvent in which the material to be deposited is dissolved or dispersed. Moreover, maintaining the original structural properties of a wide range of materials deposited from a corona generated molecular plasma was not expected, most notably as shown with a polypeptide enzyme, which maintained catalytic activity after the molecular plasma deposition. Atomic bonds are not broken during the deposition process, a factor in retaining activity and/or structural integrity of the deposited product.
In one embodiment, the process is carried out in part under atmospheric or partial pressure, and in part under vacuum. The deposition apparatus is designed to generate a corona from a solution or suspension introduced through a narrow electrified opening, such that a plasma is produced in front of a small aperture that opens into a vacuum chamber housing a substrate. Depending on the charge produced on the material dispersed in the corona plasma, the substrate is wired as an oppositely charged electrode on which the plasma particulates will deposit.
The basic structural characteristics of the deposited materials tested are not affected by the thickness of the deposit. This is in contrast to the results obtained by Storey (Breakup of Biomolecules through low-energy ion Bombardment, Master's thesis, University of Missouri, Rolla, 1998) where more than 40 or so monolayers of glycine or arginine deposited by flooding a solution of the amino acids on gold caused loss of structure, as indicated by increasing difficulty in detecting the carboxyl groups of the deposited amino acids as sample thickness increased. The disclosed molecular plasma method allows thickness to be controlled from a mono-layer of desired material to micron thickness; i.e., 2-200 microns thick while maintaining structure and activity.
The apparatus for molecular plasma deposition can be modified to accommodate a partial vacuum around the conductive tip where the corona is generated. This permits more efficient volatilization of the solvent suspending the dissolved or suspended material, so that only the material itself is drawn into the vacuum chamber housing to be deposited on the substrate and little if any solvent is present in the coating. This is necessary because, in biological applications, if the suspending solvent is also co-deposited, it may cause an adverse interaction with the deposited material. For example, if a protein that one desires to deposit on a medical implant device is dissolved in methyl alcohol, and deposited without volatilization of the alcohol before being placed in the body, the residual alcohol may cause serious physiological problems. Where little or no solvent is drawn into the chamber, it is convenient to generate the corona under atmospheric pressure conditions.
As discussed, the new method is a molecular plasma procedure for deposition of a biomolecule onto a substrate. A corona discharge plasma is generated under atmospheric or partial vacuum conditions from a liquid solution or suspension. The suspension is preferable colloidal suspension for materials that have low solubility in organic or aqueous solvents. Deposited materials may be an element, a compound, or any of a number of biomolecules. The liquid solution or suspension is ejected from a conductive point source at a high potential gradient and the resulting corona discharge is directed through an opening into an evacuated chamber where the ionized molecular plasma will be deposited onto a substrate which is maintained at an induced potential opposite from the relatively high potential at the point source where the corona is generated.
Generally, the conductive tip or point from which the colloidal suspension is ejected provides a means for atomizing the solution or liquid suspension, so that there is ready formation of a corona discharge at the high voltage tip. In many applications, one will prefer to introduce the solution or liquid suspension from the tip under atmospheric conditions, but a low or partial vacuum can also be used, preferably 100 mTorr or higher. The charged plasma then passes through a hole or orifice into an evacuated chamber; e.g., at 40 mT or less, housing a substrate held at a voltage substantially opposite to the voltage at the conductive tip. The ionized molecules in the corona plasma then deposit onto the substrate in the chamber, which is at a lower pressure than at the conductive tip where the corona is generated.
It is important to recognize that the substrate is under vacuum, typically less than 100 mTorr, preferably 40 mTorr or lower, and that if the plasma corona is formed at a tip also under reduced pressure, the substrate must be in a reduced pressure atmosphere such that the plasma can be effectively drawn into the substrate housing and deposited onto the substrate. The vacuum around the substrate is typically in the range of 40-0.1 mTorr. Additionally, the substrate must be oppositely biased in order to effect deposition from the ionized molecular plasma, which may be positive or negative depending on the material in the colloidal suspension. The ions formed in the discharge may be positive or negative. This discharge will determine the bias of the substrate; e.g., if a positive corona is used, the substrate must be negatively biased.
The amount of bias imposed on the substrate will depend on the substrate and on the area for deposition. In the examples provided herein, the substrates are approximately 4 cm 2 . The bias of the substrate is constant regardless of the size of the deposition; however, the larger the area, the higher is the current necessary to maintain constant voltage. Voltage applied to the substrate may range as high as 60 kV, which may be positively or negatively biased; i.e., opposite to the voltage at the conductive tip where the corona is generated. Typical voltages range from +15 kV through −15 kV. Where the substrate is grounded, the voltage will be zero at the substrate.
The method relies in part on efficiently generating an ionized plasma. This is accomplished by atomizing a liquid solution or suspension of the material desired for deposition through a sharp orifice or tip. This is typically a small diameter tube or needle that is imposed with a high voltage. An exemplary high voltage on an 18 gauge metal needle with an inside diameter of approximately 0.83 mm, for example, may be about −5000 volts. In this example, the voltage applied to the substrate is typically in the range of about 5000 or less volts or is zero if connected to ground.
Yet another aspect of the invention is the ability to control the corona effect for more efficient processing; e.g., for engineering surfaces. The method takes advantage of the physics of the corona effect to deposit ionized material onto a substrate, so that the material is ionically or covalently bonded to a substrate surface. This is a fast, easy way to produce an adherent coating and to structure a surface using a non-destructive technique.
The described apparatus can be used to effectively deposit a wide range of materials without significantly altering the physical, functional or chemical characteristics, by generating material into a corona plasma from a liquid solution or suspension. Materials such as proteins are preferably ionized from colloidal suspensions, due to their limited solubility in most solvents. Thymine, cytosine, adenine and guanine with respective water solubilities of 4.5 g/L, insoluble, 0.5 g/L and insoluble, are more efficiently deposited as aqueous suspensions. Almost any organic or inorganic material can be dissolved or suspended in some solvent or mixture of solvents. Materials include proteins, amino acids, peptides, polypeptides, nucleic acids and nucleic acid bases such as purines and pyrimidines, and the like. Examples of inorganic materials include compounds such as metals and metal oxides, e.g., copper oxide, elements, including carbon. In general, biological and non-biological materials that can be prepared as a solution or liquid suspension will be suitable materials for deposition. While colloidal suspensions may be preferable for some biomolecules, microparticulate suspensions may also be suitable, depending on the material, thus creating ionized molecular plasmas from liquids containing micron- or larger sized particles. Examples of material that are preferably deposited from molecular plasmas generated from colloidal suspensions include, but are not limited to: DNA, RNA, graphite, antibiotics, growth factors, growth inhibitors, viruses, inorganic compounds, catalysts, enzymes, organic compounds, and elements. Catalase is one example of a polypeptide enzyme that can be deposited by this method without loss of catalytic activity. Other proteins expected to be deposited by this method without loss of biological activity include SNAP-tag fusion proteins, hAGT fusion proteins glucose binding protein, glutamine binding protein and lactate dehydrogenase. Oxidodreductases and oxidases such as glucose oxidase are also expected to be deposited without loss of activity. Nucleotide bases such as guanine, thymine, adenine, cytosine, and uracil are examples of DNA and RNA bases that can be deposited onto a substrate from a corona generated plasma.
The solutions and liquid suspensions that are suitable for deposition may be formulated from any of a number of aqueous or organic solvents, including pure water, alcohol and water/alcohol mixtures. Some materials may be prepared in less common solvents, such as DMSO or glycols. For preferred practice of the deposition procedure, one will select a solvent or combination of solvents in which the material can be dissolved or suspended, preferably as a colloidal suspension, and which does not give rise to problems such as toxic or explosive fumes.
Definitions
Biomolecules are intended to include compounds and agents that have some biological effect or use in the body and may include, without limitation, proteins, peptides, amino acids, nucleic acids and compounds having drug activity or related to drug activity. As used herein, biomolecules also include carbon and carbon based compounds and elements and compounds such as copper oxide that may be used as coating materials on medical devices.
Colloidal particles are finely divided particles approximately 10 to 10,000 angstroms in size, dispersed within a continuous medium. The particles are not easily filtered and settle slowly over a period of time.
Nano particles are about 100 nanometers or less in size.
Ionic Plasma Deposition (IPD) is the vacuum deposition of ionized material generated in a plasma, generally by applying high voltage or high current to a cathode target where the ionized plasma particles are deposited on a substrate which acts as an anode.
A corona is produced by a process by which a current, perhaps sustained, develops from an electrode with a high potential in a neutral fluid, such as air, by ionizing the fluid to create a plasma around the electrode. The ions generated eventually transfer a charge to nearby areas of lower potential, or recombine to form neutral gas molecules.
Voltage bias is the potential, relative to earth ground, at which substrate is held. Potential ranges from zero to 15,000 volts and can be positive or negative. The potential on the substrate for biasing depends on the potential of the corona and is typically equal and opposite of this potential. Voltage may be as high as 60 kV but more typically is in the range of 5-10 kV. Where the corona plasma is +5000 volts, bias voltage for the substrate will be −5000 volts, all relative to earth ground.
As used herein, substantial or substantially means that a range is intended, on the order of plus or minus ten percent and is not intended to be limited to an exact number; for example, substantial function may include different or less than original function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sketch of the molecular plasma deposition apparatus: vacuum chamber 1 ; high voltage power supply 2 , substrate holder 3 ; substrate 4 ; high voltage power supply 5 ; needle 6 ; feeder tube to needle 7 ; orifice 15 into reservoir 8 ; colloidal liquid suspension 9 .
FIG. 2 is a sketch of a modification of the apparatus of FIG. 1 : vacuum chamber 1 ; high voltage power supply 2 ; substrate holder 3 ; substrate 4 ; high voltage power supply 5 ; needle 6 ; feeder tube 7 ; orifice 15 into reservoir 8 ; liquid suspension 9 ; secondary chamber 10 ; secondary chamber gas supply 11 ; secondary chamber gas supply line 12 ; pressure regulator 13 ; gas line from regulator 14 .
FIG. 3 is a representation of the electric field equation for a point charge.
DETAILED DESCRIPTION
The present invention takes advantage of the corona effect and the effect of corona discharge in creating a charged plasma that can be directed to a substrate surface. The basic apparatus is shown in FIG. 1 and FIG. 2 . In an exemplary procedure, a high voltage of 5 kV or higher is applied to the needle or other hollow bore, sharp pointed, conductive material. A solution or liquid suspension is passed through the hollow bore. The high electric field at the tip of the needle causes atomization of the liquid as the result of the corona effect. The molecules in the solution or suspension become charged, yet remain intact. The needle is positioned in front of a grounded, differentially pumped high vacuum system with a small hole in the chamber housing the substrate. The substrate is placed inside the evacuated chamber at a potential opposite or nearly opposite to that imposed on the needle or is set to ground (zero). The charged molecules within the corona travel through the opening toward the substrate and become deposited or attached to the substrate, becoming ionically or covalently bonded.
The entire apparatus is enclosed in an environmentally controlled chamber into which selected gases such as oxygen or nitrogen may be introduced; for example, if oxidation is desired, to control deposition rate, or to perform the deposition in an inert atmosphere. Mixtures of gases may be introduced, including other inert gases such as xenon, argon, helium or combinations of gases.
The molecular plasma generation process can also be run at lower than atmospheric pressures, i.e., under reduced pressure, in the presence of gases other than atmospheric, (e.g., argon or oxygen background atmosphere). When the molecular plasma at the conductive tip is generated under reduced pressure, the pressure in the chamber housing the substrate must be lower so that the plasma discharge passes readily through the opening into the chamber housing the substrate, as shown in FIG. 1 .
As shown in FIG. 1 , the molecular plasma generation apparatus provides a system for producing a plasma discharge under atmospheric conditions by passing a liquid colloidal suspension 9 through a discharge needle 6 at a high voltage 5 . The resulting atomized liquid forms an ionized plasma in the atmosphere. The plasma passes through an orifice 15 in the vacuum chamber 1 housing the substrate 4 on the substrate holder 3 . A power supply 2 provides voltage to the substrate 4 at a voltage opposite to that provided by the power supply 5 to the discharge needle 6 .
FIG. 2 illustrates an alternative embodiment of a system for producing an ionized plasma discharge. A reservoir 8 , feeds a solution or liquid suspension of the material 9 through an orifice 15 for deposition of the colloidal material on the substrate 4 . The liquid is passed through the highly charged needle 6 from the power supply 5 . In this embodiment, the feeder and needle are housed in a second chamber 10 which can be pressure regulated by a pressure control 13 through the opening 14 into the secondary chamber. The atmosphere within the secondary chamber 10 can be modified from a gas container 11 having a conduit 12 passing through the regulator 13 . The vacuum chamber 1 is maintained at a lower pressure than in chamber 10 . The substrate 4 is biased using the power supply 2 at a voltage opposite to that supplied by power supply 5 to the needle 6 .
Liquid suspensions or solutions may be prepared in organic or inorganic liquids, which should not be toxic or flammable. Most materials are preferably prepared as aqueous solutions or may be prepared in organic acids such as acetic acid, propionic acid, halogen substituted acetic acid, oxalic acid, malonic acid and/or hydroxycarboxylic acids alone or with water. Liquid mixtures may include salts or organic/water miscible preparations. Examples of alcohols include ethanol, methanol, and ketones such as acetone, DMF, THF and methylethylketone. Amino acids, for example, may be water soluble at low concentrations but form colloidal suspensions at higher concentrations. Lysine and threonine are highly water soluble while tyrosine has a limited solubility of about 0.045 g/100 ml at 25° C.
BACKGROUND DESCRIPTION OF CORONAS AND ELECTRICAL DISCHARGES
Corona discharge of both the positive and negative variety is commonly characterized as ionization of a neutral atom or molecule in a region of strong electrical field typically in the high potential gradient near a curved electrode, creating a positive ion and a free electron. The electric field then separates and accelerates the charged particles preventing recombination and imparting each particle with kinetic energy. Energized electrons, which have a much higher charge/mass ratio and so are accelerated to a higher velocity, may create additional electron/positive-ion pairs by collision with neutral atoms. These then undergo the same separating process, giving rise to an electron avalanche. Both positive and negative coronas rely on electron avalanches. FIG. 3 illustrates a typical point charge formed in a strong electrical field.
The energy of these plasma processes is converted into initial electron dissociations to seed further avalanches. An ion species created in this series of avalanches, which differs between positive and negative coronas, is attracted to an uncurved electrode, e.g., a flat surface, completing the circuit, and sustaining the current flow.
A corona is a process by which a current, whether or not sustained, develops from an electrode with a high potential gradient in a neutral fluid, usually air. When the potential gradient is large enough at a point in the fluid, the fluid at that point ionizes and it becomes conductive. If a charged object has a sharp point, the air around that point will be at a higher gradient than elsewhere, and can become conductive while other points in the air do not. When the air becomes conductive, it effectively increases the size of the conductor. If the new conductive region is less sharp, the ionization may not extend past this local region. Outside of this region of ionization and conductivity, the charged particles slowly find their way to an oppositely charged object and are neutralized. On the other hand, if the geometry and gradient are such that the ionized region continues to grow instead of stopping at a certain radius, a completely conductive path is formed, and a momentary or continuous spark or arc occurs.
Corona discharge usually involves two asymmetric electrodes, one highly curved, such as the tip of a needle, or a narrow wire, and one of low curvature, such as a plate, or the ground. The high curvature ensures a high potential gradient around one electrode inn order to effectively generate a plasma.
Coronas may be positive or negative. This is determined by the polarity of the voltage on the highly-curved electrode. If the curved electrode is positive with respect to the flat electrode the corona is positive; if the electrode is negative, a negative corona exists. The physics of positive and negative coronas are strikingly different. This asymmetry is a result of the large difference in mass between electrons and positively charged ions, with only the electron having the ability to undergo a significant degree of ionizing inelastic collisions at standard temperatures and pressures.
A negative corona is manifested as a non-uniform corona, varying according to the surface features and irregularities of the curved conductor. It often appears as tufts of corona at sharp edges, the number of tufts changing with the strength of the field. The form of negative coronas is a result of its source of secondary avalanche electrons. It appears a little larger than the corresponding positive corona, as electrons are allowed to drift out of the ionizing region, allowing the plasma to continue some distance beyond it. The total number of electrons and electron density is much greater than in the corresponding positive corona; however, the electrons are at a predominantly lower energy, owing to being in a region of lower potential-gradient. Therefore, while for many reactions the increased electron density will increase the reaction rate, the lower energy of the electrons means that reactions which require a higher electron energy may take place at a lower rate.
A positive corona is manifests as a uniform plasma across the length of a conductor. It is often observed as a blue/white glow, although much of the emission is in the ultraviolet. The uniformity of the plasma is due to the homogeneous source of secondary avalanche electrons. With the same geometry and voltages, a positive corona appears somewhat smaller than the corresponding negative corona, owing to the lack of a non-ionizing plasma region between the inner and outer regions. There are many fewer free electrons in a positive corona, perhaps a thousandth of the electron density, and a hundredth of the total number of electrons, compared to a negative corona, with the exception of the area close to the curved electrode where electrons are highly concentrated. This region has a high potential gradient, causing the electrons to have higher energy. Most of the electrons in a negative corona are in outer, lower energy field areas.
In a positive corona, secondary electrons, giving rise to additional avalanches, are generated predominantly in the fluid itself, in the region outside the plasma or avalanche region. They are created by ionization caused by the photons emitted from that plasma in the various de-excitation processes occurring within the plasma after electron collisions. The thermal energy liberated in those collisions creates photons which are radiated into the gas. The electrons resulting from the ionization of a neutral gas molecule are then electrically attracted back toward the curved electrode and into the plasma, cycling the process of creating further avalanches inside the plasma.
The positive corona is divided into two regions, concentric around the sharp electrode. The inner region contains ionizing electrons, and positive ions, acting as a plasma, the electrons avalanche in this region, creating many further ion/electron pairs. The outer region consists almost entirely of the slowly migrating massive positive ions, moving toward the uncurved electrode along with, close to the interface of this region, secondary electrons, liberated by photons leaving the plasma, being re-accelerated into the plasma. The inner region is known as the plasma region, the outer as the unipolar region.
A negative corona is manifested as a non-uniform corona, varying according to the surface features and irregularities of the curved conductor. It often appears as tufts of corona at sharp edges, the number of tufts altering with the strength of the field. The form of negative coronas is a result of its source of secondary avalanche electrons. The negative corona appears a little larger than the corresponding positive corona, due to drifting of the electrons from the ionizing region, so that the plasma continues some distance beyond it. The total number of electrons, and accordingly the electron density, is much greater than in the corresponding positive corona. The electrons are lower energy that those in a positive corona because they are in a region of lower potential-gradient.
Negative coronas are more complex than positive coronas in construction. As with positive coronas, the establishing of a corona begins with an exogenous ionization event generating a primary electron, followed by an electron avalanche.
The difference between positive and negative coronas is in the generation of secondary electron avalanches. In a positive corona the avalanches are generated by the gas surrounding the plasma region, the new secondary electrons traveling inward, while in a negative corona they are generated by the curved electrode itself, the new secondary electrons traveling outward.
An additional structural feature of negative coronas is the outward drift of the electrons, where they encounter neutral molecules and may combine with electronegative molecules such as oxygen and or water vapor to produce negative ions. These negative ions are then attracted to a positive uncurved electrode, completing the ‘circuit’.
A negative corona can be divided into three radial areas, around the sharp electrode. In the inner area, high-energy electrons inelastically collide with neutral atoms and cause avalanches, while outer electrons, usually of a lower energy, combine with neutral atoms to produce negative ions. In the intermediate region, electrons combine to form negative ions, but typically have insufficient energy to cause avalanche ionization. They remain part of a plasma owing to the different polarities of the species present, and the ability to participate in characteristic plasma reactions. In the outer region, only a flow of negative ions and, to a lesser and radially-decreasing extent, free electron movement toward the positive electrode takes place. The inner two regions are known as the corona plasma. The inner region is an ionizing plasma, the middle a non-ionizing plasma. The outer region is known as the unipolar region.
As discussed, the corona principal has been used to create an approximately infinite electric field at the point of a sharp needle. For practical purposes, it can be assumed that the tip of the device is atomically sharp and closely approximates a point charge. This is because as r goes to zero, E approaches infinity. A corona effect is initiated at the tip of the device.
The energy of the electrons and relation to the distance from the point source of generation is based on the electric field of a point charge derived from Coulomb's law. This law states the electric field from any number of point charges can be obtained from a vector sum of the individual fields. A positive number is taken to be an outward field; the field of a negative charge is toward it. This can be shown in equation 1 and illustrated in FIG. 3 :
E
=
F
q
=
k
Q
source
q
qr
2
=
kQ
source
r
2
1
EXAMPLES
The following examples are intended only as illustrations of the invention and are in no way to be considered limiting for what is described and taught herein.
Example 1—Apparatus for Molecular Plasma Deposition
An exemplary apparatus includes a vacuum chamber with a small aperture, and a small bore, metallic needle connected to a tube connected to a reservoir holding a liquid suspension or solution of the material desired to be deposited. The reservoir is at atmospheric pressure. A power supply with the ability to supply up to 60 kV can be employed; however, as used in the examples herein, the voltage attached to the needle is typically −5000 volts to +5000 volts. A substrate inside the vacuum chamber, is centered on the aperture with a bias from −60 kV through −60 kV, including ground. The apparatus is illustrated in FIG. 1 .
Example 2—Apparatus for Molecular Plasma Generation under Selected Environments
The apparatus illustrated in FIG. 2 can be modified such that the needle, tube, and reservoir are disposed in an enclosure that excludes air, but allows for the controlled introduction of other gases. Optionally selected gases include argon, oxygen, nitrogen, xenon, hydrogen, krypton, radon, chlorine, helium, ammonia, fluorine and combinations of these gases.
Example 3—Apparatus for Corona Discharge Generation Under Reduced Pressure
In the apparatus shown in FIG. 1 , the pressure differential between the corona discharge and the substrate is about one atmosphere. The outside pressure of the vacuum chamber is approximately 760 Torr, whereas pressure in the area of the substrate is approximately 0.1 Torr.
The apparatus shown in FIG. 2 , on the other hand, can be optionally operated at a pre-determined pressure above or below atmospheric pressure. While atmospheric pressure is generally preferred for generation of the plasma, reduced pressure up to about 100 mTorr may in some instances provide satisfactory depositions.
Example 4—Molecular Plasma Deposition of Amino Acids
This example illustrates deposition of a suspension of amino acids onto a gold rod. A colloidal suspension of a mixture of the amino acids glycine (solubility of 20 g/l at 25° C.), alanine (166.5 g/l), valine (88.5 g/l), leucine (24.26 g/l) and arginine (235.8 g/l) in water was deposited using the apparatus of Example 1 onto a gold covered rod, ⅛″ in diameter and approximately 0.75 cm 2 . The power supply was attached to a 304 stainless steel 18 gauge needle and set at −5000 V. The gold substrate was set at a potential of 5000 V. The substrate was centered on the hole in the chamber and placed 5 cm from the hole. The vacuum chamber was pumped to 40 mTorr and the flow of the colloidal suspension was initiated. The deposition was carried out for 30 min.
The coated rod was placed in a time-of-flight secondary ion mass spectrometer (TOF-SIMS) and the components were analyzed for composition. Results showed that the amino acids were deposited intact and ionically bonded to the substrate. Mass over charge calculations in conjunction with the time of flight spectrometry were used to calculate the masses of the incoming species. These calculations were used to interpret the spectra from the SIMS. The m/q data showed the amino acids being ejected intact from the surface.
In a control comparison experiment, the substrate was dipped into the amino acid mixture and analyzed by TOF-SIMS as above. These spectra were subtracted from amino acid spectra generated from corona deposition in order to isolate any effects that occurred due only to the deposition method. Fragmentation was observed in both spectra, and after subtraction, it was determined that the fragmentation was an effect of the analytic technique, not the deposition technique because the fragmentation occurred equally in both spectra.
Example 5—Molecular Plasma Deposition of Graphite
A colloidal suspension of graphite powder in isopropyl alcohol (10 g/1001 ml) was deposited onto an aluminum oxide substrate using the apparatus shown in FIG. 1 .
The power supply was attached to a 304 stainless steel 18 gauge needle and set at −5000V. The aluminum oxide substrate was connected to ground. The substrate was centered on the hole in the chamber and placed 5 cm from the hole. The vacuum chamber was pumped to 40 mTorr and the flow of the colloidal suspension was initiated. The deposition was carried out for 30 minutes. The substrate was removed from the chamber and a simple ohm meter resistance test performed. Resistance of the substrate changed from infinite to 1 ohm over the 30 min deposition period.
Example 6—Molecular Plasma Deposition of Copper Oxide
A colloidal suspension of copper oxide powder in water (10 g/100 ml) was prepared. Using the apparatus illustrated in FIG. 2 , the high voltage power supply was attached to a 304 stainless steel, 18 gauge needle set at −10,000V. The substrate was 304 stainless steel and set at a potential of 5000 V. The substrate was centered and placed 5 cm from the hole in the chamber. The chamber was pumped to 40 mTorr and the flow of the colloidal suspension initiated. The deposition onto the substrate was allowed to proceed for 10 minutes. At the end of the deposition process, the substrate was removed from the chamber and a simple tape test showed good adhesion of the deposited copper oxide. Good adhesion between the substrate and the copper oxide were confirmed by repeating the tape test and by observing that after sonicating the coated sample for 10 min there was no evidence of flaking or sloughing.
Example 7—Molecular Plasma Deposition of RNA and DNA Bases
A colloidal suspension of guanine, adenine, cytosine, uracil and thymine in water (each at 5 g/100 ml) was deposited onto gold covered rod having a surface of approximately 0.75 cm 2 area, ⅛″ diameter, using the apparatus of Example 1. The power supply was attached to a 304 stainless steel 18 gauge needle and set at −5000V. The gold substrate was set at a potential of 5000 V. The substrate was centered on the hole in the chamber and placed 5 cm from the hole. The vacuum chamber was pumped to 40 mTorr and the flow of the colloidal suspension was initiated. The deposition was carried out for 30 min.
The coated rod was placed in a time-of-flight secondary ion mass spectrometer (TOF-SIMS) and the components were analyzed for composition. Results showed that the DNA bases were deposited intact and ionically bonded to the substrate. Mass over charge calculations in conjunction with the time of flight spectrometry were used to calculate the masses of the incoming species.
These calculations were used to interpret the spectra from the SIMS. The m/q data showed the bases being ejected from the surface as being intact. Spectra from another deposition method (dipping the substrate in a mixture containing the bases) ware also analyzed as a control to the bases deposited using the corona effect. The spectra was subtracted from the corona effect spectrum to isolate any effects that occurred due only to the deposition method. Fragmentation was observed in both spectra, and once subtracted, it was determined this observation was a product of the analytic technique and not the deposition technique because the fragmentation occurred equally in both spectra.
Example 8—Molecular Plasma Deposition of Catalase
25 ml of a 2× crystallized bovine liver catalase (Sigma C100-58MG; 056K7010) colloidal suspension in water with 0.1% thymol was prepared. Protein concentration was 33 mg/ml with an activity of 4.1×10 4 U/ml.
Using the apparatus illustrated in FIG. 2 , the high voltage power supply was attached to a 304 stainless steel, 18 gauge needle set at −5000V. The substrate was an aluminum oxide disk ¼″ thick by 1.5″ in diameter, having an area of approximately 11 sq cm and set at a potential of 5000 V. The substrate was centered and placed 5 cm from the hole in the chamber. The chamber was pumped to 40 mTorr and the flow of the colloidal suspension initiated. The deposition onto the substrate was allowed to proceed for 10 minutes. At the end of the deposition process, the substrate was removed from the chamber and the sample was placed in a 5% solution of hydrogen peroxide. The results showed the catalysis of the hydrogen peroxide by the catalase, producing bubbling of oxygen from the surface, showing that the enzyme remained intact throughout the deposition process.
The deposition was repeated twice under the same conditions, except that after the substrate was removed from the chamber, the samples were placed in an ultrasonic water bath for 10 min. Additionally, one of the samples was maintained at 10° C. for 72 hr after removal from the bath. In each case, exposure of the sample to a 5% solution of hydrogen peroxide produced bubbling of oxygen from the surface of the substrate. The ultrasonic treatment did not affect the deposited material, indicating that a stable, adherent coating of catalase had been deposited.
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A molecular plasma discharge deposition method for depositing colloidal suspensions of biomaterials such as amino acids or other carbon based substances onto metal or nonmetal surfaces without loss of biological activity and/or structure is described. The method is based on generating a charged corona plasma which is then introduced into a vacuum chamber to deposit the biomaterial onto a biased substrate. The deposited biomaterials can be selected for a variety of medical uses, including coated implants for in situ release of pharmaceuticals.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No. 11/499,076 filed 4 Aug. 2006, which claims priority from U.S. provisional patent application Ser. No. 60/705,966, filed 5 Aug. 2005. The contents of these applications are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0002] The present invention relates to methods of preparing quinolone analogs. The compounds prepared according to the methods of the present invention may exhibit one or more of the following activities: inhibit cell proliferation, induce cell apoptosis and stabilize a quadrupled structure.
[0003] In one aspect, the present invention provides a method for preparing a compound having formula 1:
[0000]
and pharmaceutically acceptable salts, esters and prodrugs thereof, wherein:
[0005] A, V, and Z are independently H, halo, cyano, R 2 , CH 2 R 2 , SR 2 , OR 2 or NR 1 R 2 ; or
[0006] wherein A and Z, or V and Z may form a carbocyclic ring, heterocyclic ring, aryl or heteroaryl, each of which may be optionally substituted and/or fused with a cyclic ring;
[0007] W is NR 1 R 2 or OR 6 wherein R 6 is a C 1-10 alkyl;
[0008] X is O, S, CR 1 or NR 1 ;
[0009] each R 1 is H or a C 1-6 alkyl;
[0010] each R 2 is H, or a C 1-10 alkyl or C 2-10 alkenyl each optionally substituted with a halogen, one or more non-adjacent heteroatoms, a carbocyclic ring, a heterocyclic ring, an aryl or heteroaryl, wherein each ring is optionally substituted;
[0011] R is a substituent at any position on B; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by one or more non-adjacent heteroatoms; or two adjacent R are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring;
[0012] B is an optionally substituted ring, which may be aromatic or nonaromatic, and may be monocyclic or fused with a single or multiple ring, wherein said single or multiple ring may optionally contain one or more heteroatoms;
[0013] n is 1-6;
[0014] or a compound having formula (2A) or (4A):
[0000]
[0015] wherein n, V, Z, X, W, B and R are as defined in formula (1), comprising:
[0016] contacting a compound having formula (6A), (6B) or (6C)
[0000]
[0017] wherein each L and L 1 is a leaving group; and A, V, and Z are as defined in formula (1);
[0018] with a compound having formula (7) and tautomers thereof
[0000]
[0019] wherein n, X, B and R are as defined in formula (1); and
[0020] W is OR 6 wherein R 6 is a C 1-10 alkyl; or W is NR 1 R 2 , wherein R 1 and R 2 are as defined in formula (1);
[0021] wherein said compound having formula (6A), (6B) or (6C) is contacted with said compound having formula (7) and tautomers thereof in the presence of a base to produce a compound having formula (1), and optionally hydrolyzing said compound of formula (1).
[0022] In the above method, the compound having formula (6A), (6B) or (6C) may be contacted with a compound of formula (7) or tautomers thereof in the presence of a base and coordinating atom, such as the coordinating metal of a Lewis acid.
[0023] In particular examples, the base is a non-nucleophilic base having a pKa of less than 20. Various bases known in the art may be used to practice the methods of the invention, including but not limited to triethylamine (TEA), diisopropyl ethyl amine (DIEA), diazabicycloundecene (DBU), cesium carbonate, 1,8-Bis(dimethylamino)naphthalene (Proton sponge) and dimethylamino pyridine (DMAP).
[0024] Suitable Lewis acids for use in practicing the methods of the invention may be selected by conducting a test reaction, and observing the amount of reaction product produced, as described hereafter. In one embodiment, the Lewis acid has formula ML n , wherein L is a halogen atom or an organic radical, n is 3-5, and M is a group II metal, such as MgCl 2 . Other M groups include but are not limited to group III elemental atom (e.g., B), a group IV elemental atom, As, Sb, V or Fe.
[0025] In the above method, the compound having formula (1), (2A) or (4A) wherein W is OR 6 and R 6 is a C 1-6 alkyl, may further be contacted with an amine of the formula
[0000] HNR 1 —(CR 1 2 ) n —NR 3 R 4 (3)
[0026] wherein R 1 and R 3 are independently H or C 1-6 alkyl;
[0027] n is 1-6; and
[0028] R 4 is H, a C 1-10 alkyl or C 2-10 alkenyl optionally containing one or more non-adjacent heteroatoms selected from N, O and S, and optionally substituted with a carbocyclic or heterocyclic ring; or R 3 and R 4 together with N may form an optionally substituted ring containing one or more N, O or S.
[0029] In the above formula (3), R 3 and R 4 together with N may form an optionally substituted piperidine, pyrrolidine, piperazine, morpholine, thiomorpholine, imidazole, or aminothiadiazole.
[0030] In the above method, the compound having formula (1), (2A) or (4A) wherein W is OR 6 and R 6 is a C 1-6 alkyl, may further be contacted with an amine of the formula HNR 1 R 2 , provided said amine is not NH 3 . In the amine HNR 1 R 2 , the R 1 substituent may be H, and R 2 is a C 1-10 alkyl optionally substituted with a heteroatom, a C 3-6 cycloalkyl, aryl or a 5-14 membered heterocyclic ring containing one or more N, O or S; or R 1 and R 2 together with N may form an optionally substituted heterocyclic ring containing one or more N, O or S. In one example, R 2 is a C 1-10 alkyl substituted with morpholine, thiomorpholine, imidazole, aminothiadiazole, pyrrolidine, piperazine, pyridine or piperidine; or R 1 and R 2 together with N form piperidine, pyrrolidine, piperazine, morpholine, thiomorpholine, imidazole, or aminothiadiazole.
[0031] In each of the above formula, B may be an optionally substituted phenyl. Furthermore, each R in the above formula may be H or halo. The X substituent in each of the above formula may be NR 1 or S. In other examples, one of A and V in each of the above formula is H or halo, such as a fluoro or a chloro. In each of the above formula, each Z may be H, halo, or SR 2 wherein R 2 is C 1-10 alkyl.
[0032] In the above formula (6A), (6B) or (6C), each L and L 1 is suitable leaving group such as halo, sulfonate, sulfoxide, sulfone, acyloxy, phosphonate, imidazole, benzotriazole, or imide. Other leaving groups which may be suitable for use in the methods of the invention include but are not limited to tosylate, alkyl sulfonyl, carbonate, acetate, carbamate, trifluoroacetate, phosphate, methoxy or activated methoxy, nitro, boron, or a substituted boron such as boronate esters.
[0033] In the above methods, a compound having formula (6A), (6B) or (6C) may be contacted with a compound having formula (7) to form a mixture, and further contacting the mixture with a base. The mixture may be cooled to a temperature below room temperature prior to addition of base. Alternatively, the base may be added to the mixture at room temperature or at a temperature above room temperature. In particular examples, the base is an amine, such as trialkylamine.
[0034] In one aspect, the methods of the present invention may be used to prepare a compound having formula (2B), (4), (4B) or (5A):
[0000]
[0035] wherein n, W, V, A, Z, X, B and R are as defined in formula (1).
[0036] In another aspect, the present invention provides methods for preparing a compound having formula (8)
[0000]
[0037] wherein V, A, Z, and Y when attached to C are independently H, halo, azido, R 2 , CH 2 R 2 , SR 2 , OR 2 , NR 1 R 2 ; or absent when attached to N;
[0038] T 1 , T 2 , T 3 , and T are independently C, N or S;
[0039] W is NR 1 R 2 or OR 6 , wherein R 6 is a C 1-10 alkyl;
[0040] X is O, S, CR 1 or NR 1 ;
[0041] E together with N and X form a ring, which may be fused with a single or multiple ring, wherein the single or multiple ring optionally contains one or more heteroatoms;
[0042] n is 1-6;
[0043] p is 0-1;
[0044] each R 1 is H or a C 1-6 alkyl;
[0045] each R 2 is H, or a C 1-10 alkyl or C 2-10 alkenyl each optionally substituted with a halogen, one or more non-adjacent heteroatoms, a carbocyclic ring, a heterocyclic ring, an aryl or heteroaryl, wherein each ring is optionally substituted;
[0046] R 5 is a substituent at any position on E; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by one or more non-adjacent heteroatoms; or two adjacent R 5 are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring;
[0047] comprising contacting a compound having a formula (9) with a compound having formula (10) and tautomers thereof:
[0000]
[0048] wherein n, V, A, Z, Y, T 1 , T 2 , T 3 , T 4 , X, W, E and R 5 are as defined in formula (8); and
[0049] each L and L 1 is a leaving group.
[0050] In the above method, the compound having formula (9) may be contacted with a compound of formula (10) or tautomers thereof in the presence of a base and coordinating atom such as the coordinating metal of a Lewis acid. Various bases and Lewis acids, such as those previously described and which would be known to those skilled in the art, may be used.
[0051] In the above formula (8), each T 1 , T 2 , T 3 and may be C. In another embodiment, T 1 is N, and each T 2 , T 3 , and T 4 is C. In yet another embodiment, T 2 is N, and each T 1 , T 3 , and T 4 is C. In other embodiments, each T 1 and T 3 is N, and each T 2 and T 4 is C. In another embodiment, each T 1 and T 4 is N, and each T 2 and T 3 is C. In yet another embodiment, each T 1 , T 2 , and T 3 is CR 1 , and is N.
[0052] In yet another embodiment, p in formula (8) is 0, T 2 and T 3 are C and T 4 is S.
[0053] In the above formula (9), each L and L 1 may be halo, tosylate, alkyl sulfonyl, carbonate, acetate, carbamate, trifluoroacetate, phosphate, methoxy or activated methoxy, nitro, boron, or a substituted boron such as boronate esters. Other leaving groups which may be suitable for use in the methods of the invention include but are not limited to sulfonate, sulfoxide, sulfone, acyloxy, phosphonate, imidazole, benzotriazole, or imide. In particular embodiments, each L and L 1 is halo.
[0054] In the above formula (10), W may be OR 6 and R 6 is a C 1-6 alkyl. Furthermore, the double bond linked to N in formula (10) may be delocalized, and the compound may be converted to its tautomeric isomer.
[0055] In the above formula (8) and (10), E together with N may be a 5-6 membered heteroaryl, or E may be selected from the group consisting of
[0000]
[0056] wherein X is O, S, CR 1 or NR 1 ;
[0057] X 1 and X 2 are independently CR 1 or NR 1 ;
[0058] each R 1 is H or C 1-6 alkyl;
[0059] R and n are as defined in formula (8).
[0060] In yet another aspect, the present invention provides a method for preparing a compound having formula (11):
[0000]
[0061] and pharmaceutically acceptable salts, esters and prodrugs thereof;
[0062] wherein V, X, and Y are absent if attached to a heteroatom other than Nitrogen, and independently H, halo, azido, R 2 , CH 2 R 2 , SR 2 , OR 2 or NR 1 R 2 when attached to C or N; or
[0063] wherein V and X, or X and Y may form a carbocyclic ring, heterocyclic ring, aryl or heteroaryl, each of which may be optionally substituted and/or fused with a cyclic ring;
[0064] Z 1 , Z 2 and Z 3 are C, N, O or S;
[0065] Z is O, S, NR 2 , CH 2 or C═O;
[0066] E together with N and Z forms an optionally substituted 5- or 6-membered ring that is fused to an optionally substituted aryl or heteroaryl, wherein said aryl or heteroaryl may be monocyclic or fused with a single or multiple ring, and wherein said single or multiple ring optionally contains one or more heteroatoms;
[0067] U is R 2 , OR 2 , NR 1 R 2 , NR 1 —(CR 1 2 ) n —NR 3 R 2 , SO 3 R 2 , SO 2 NR 1 R 2 or SO 2 NR 1 —(CR 1 2 ) n —NR 3 R 4 ;
[0068] wherein in each NR 1 R 2 , R 1 and R 2 together with N may form an optionally substituted ring;
[0069] in NR 3 R 4 , R 3 and R 4 together with N may form an optionally substituted ring;
[0070] R 1 and R 3 are independently H or C 1-6 alkyl;
[0071] each R 2 is H, or a C 1-10 alkyl or C 2-10 alkenyl each optionally substituted with a halogen, one or more non-adjacent heteroatoms selected from N, O and S, a carbocyclic ring, a heterocyclic ring, an aryl or heteroaryl, wherein each ring is optionally substituted; or R 2 is an optionally substituted carbocyclic ring, heterocyclic ring, aryl or heteroaryl; or R 2 is COR 1 or S(O) x R 1 wherein x is 1-2;
[0072] R 4 is H, a C 1-10 alkyl or C 2-10 alkenyl optionally containing one or more non-adjacent heteroatoms selected from N, O and S, and optionally substituted with a carbocyclic or heterocyclic ring; or R 3 and R 4 together with N may form an optionally substituted ring;
[0073] each R 5 is a substituent at any position on W; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R 5 is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by halo, carbonyl or one or more non-adjacent heteroatoms; or two adjacent R 5 are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring; and
[0074] n is 1-6.
[0075] In the above formula (11), ring T may form an optionally substituted 5-membered ring selected from the group consisting of:
[0000]
[0076] In the above formula (11), E together with N and Z may form a 5- or 6-membered ring that is fused to a phenyl, or E may be selected from the group consisting of
[0000]
[0077] wherein X is O, S, CR 1 or NR 1 ;
[0078] X 1 and X 2 are independently CR 1 or NR 1 ;
[0079] each R 1 is H or C 1-6 alkyl;
[0080] R and n are as defined in formula (8).
[0081] In one embodiment, the methods of the invention may be used to prepare compounds having general formula (12A) or (12B):
[0000]
[0082] wherein U, V, E, X, y, Z, Z 1 , Z 2 , Z 3 , R 5 and n are as described in formula (11);
[0083] Z 4 is CR 6 , NR 2 , or C═O; and
[0084] Z and Z 4 may optionally form a double bond.
[0085] In yet another embodiment, the methods of the invention may be used to prepare compounds having general formula (13), (14) and (15)
[0000]
[0086] wherein U, V, X, Y, Z, Z 1 , Z 2 , Z 3 , R 5 and n are as described in formula (11).
[0087] The compounds prepared according to the methods of the present invention are useful for ameliorating a cell proliferative disorder such as a tumor or a cancer; or are intermediates to such compounds. The cancer may be pancreatic cancer, including non-endocrine and endocrine tumors. Illustrative examples of non-endocrine tumors include but are not limited to adenocarcinomas, acinar cell carcinomas, adenosquamous carcinomas, giant cell tumors, intraductal papillary mucinous neoplasms, mucinous cystadenocarcinomas, pancreatoblastomas, serous cystadenomas, solid and pseudopapillary tumors. An endocrine tumor may be an islet cell tumor.
[0088] The compounds prepared according to the methods of the present invention are also useful for reducing cell proliferation and/or inducing cell death, such as apoptosis or apoptotic cell death, in a system or a subject; or are intermediates to such compounds. The system may be a cell or a tissue. In one embodiment, the system includes a pancreatic cell, such as a cell from a subject or a cultured cell (e.g., in vitro or ex vivo). In particular embodiments, the system includes a pancreatic cancer cell. In one embodiment, the system is a cell line such as PC3, HCT116, HT29, MIA Paca-2, HPAC, Hs700T, Panc10.05, Panc 02.13, PL45, SW 190, Hs 766T, CFPAC-1 and PANC-1. The subject may be human or animal. Furthermore, the compounds prepared according to the methods of the present invention are useful for reducing microbial titers and/or for ameliorating a microbial infection; or are intermediates to such compounds. The microbial titers may be viral, bacterial or fungal titers.
DEFINITIONS
[0089] As used herein, the term “alkyl” refers to a carbon-containing compound, and encompasses groups containing one or more heteroatoms. The term “alkyl” also encompasses alkyls substituted with one or more substituents including but not limited to OR 1 , amino, amido, halo, ═O, aryl, heterocyclic groups, or inorganic substituents.
[0090] As used herein, the term “carbocycle” refers to a cyclic compound containing only carbon atoms in the ring, whereas a “heterocycle” refers to a cyclic compound comprising a heteroatom. The carbocyclic and heterocyclic structures encompass compounds having monocyclic, bicyclic or multiple ring systems.
[0091] As used herein, the term “aryl” refers to a polyunsaturated, typically aromatic hydrocarbon substituent, whereas a “heteroaryl” or “heteroaromatic” refer to an aromatic ring containing at least one heteroatom selected from N, O and S. The aryl and heteroaryl structures encompass compounds having monocyclic, bicyclic or multiple ring systems.
[0092] As used herein, the term “heteroatom” refers to any atom that is not carbon or hydrogen, such as nitrogen, oxygen or sulfur.
[0093] Illustrative examples of heterocycles include but are not limited to tetrahydrofuran, 1,3-dioxolane, 2,3-dihydrofuran, pyran, tetrahydropyran, benzofuran, isobenzofuran, 1,3-dihydro-isobenzofuran, isoxazole, 4,5-dihydroisoxazole, piperidine, pyrrolidine, pyrrolidin-2-one, pyrrole, pyridine, pyrimidine, octahydro-pyrrolo[3,4-b]pyridine, piperazine, pyrazine, morpholine, thiomorpholine, imidazole, imidazolidine-2,4-dione, 1,3-dihydrobenzimidazol-2-one, indole, thiazole, benzothiazole, thiadiazole, thiophene, tetrahydro-thiophene 1,1-dioxide, diazepine, triazole, guanidine, diazabicyclo[2.2.1]heptane, 2,5-diazabicyclo[2.2.1]heptane, 2,3,4,4a,9,9a-hexahydro-1H-β-carboline, oxirane, oxetane, tetrahydropyran, dioxane, lactones, aziridine, azetidine, piperidine, lactams, and may also encompass heteroaryls. Other illustrative examples of heteroaryls include but are not limited to furan, pyrrole, pyridine, pyrimidine, imidazole, benzimidazole and triazole.
[0094] As used herein, the term “Lewis acid” refers to any species that can accept an electron pair, such as metal ions and electron-deficient molecules. In one example, the methods of the present invention use a Lewis acid such as magnesium chloride. Other Lewis acids may be used in practicing the methods of the present invention, including species having the formula ML n , wherein L is a halogen atom or an organic radical such as an alkyl group, n is 3-5, and M is a group III elemental atom (e.g., B, Al, Ga, In), or a group IV elemental atom (e.g., Zr, Ti, Sn). Strong Lewis acidity is also observed for certain group V elemental atoms (e.g., As, Sb, V), and group VIII elemental atoms (e.g., Fe). Group II elemental atoms (e.g., Zn, Cd) generally display moderate Lewis acidity. Particular Lewis acids that may be used to practice the methods of the present invention include but are not limited to: MgL 2 ; BL 3 ; AlL 3 ; FeL 3 ; GaL 3 ; SbL 5 ; InL 3 ; ZrL 4 ; SnL 4 ; TiL 4 ; TiL 3 ; AsL 3 ; SbL 3 . (See, e.g., D. P. N. Satchell & R. S. Satchell, Quantitative Aspects of the Lewis Acidity of Covalent Metal Halides and their Organo Derivatives, 69 C HEM . R EV. 251, 253-55 (1969)).
[0095] As used herein, the term “apoptosis” refers to an intrinsic cell self-destruction or suicide program. In response to a triggering stimulus, cells undergo a cascade of events including cell shrinkage, blebbing of cell membranes and chromatic condensation and fragmentation. These events culminate in cell conversion to clusters of membrane-bound particles (apoptotic bodies), which are thereafter engulfed by macrophages.
DESCRIPTION OF THE INVENTION
[0096] The present invention relates to the preparation of compounds having any one of formula (1), (2A), (2B), (4), (4A), (4B), (5A), (5B), (8), (11), (12A), (12B) and 13-15 and pharmaceutically acceptable salts, esters, and prodrugs thereof. The compounds may interact with regions of DNA that can form quadruplexes, and may also be used for treatment of cell proliferative disorders.
[0097] In one aspect, the present invention provides a method for preparing a compound having formula 1:
[0000]
[0098] and pharmaceutically acceptable salts, esters and prodrugs thereof, wherein:
[0099] A, V, and Z are independently H, halo, cyano, R 2 , CH 2 R 2 , SR 2 , OR 2 or NR 1 R 2 ; or
[0100] wherein A and Z, or V and Z may form a carbocyclic ring, heterocyclic ring, aryl or heteroaryl, each of which may be optionally substituted and/or fused with a cyclic ring;
[0101] W is NR 1 R 2 or OR 6 wherein R 6 is a C 1-10 alkyl;
[0102] X is O, S, CR 1 or NR 1 ;
[0103] each R 1 is H or a C 1-6 alkyl;
[0104] each R 2 is H, or a C 1-10 alkyl or C 2-10 alkenyl each optionally substituted with a halogen, one or more non-adjacent heteroatoms, a carbocyclic ring, a heterocyclic ring, an aryl or heteroaryl, wherein each ring is optionally substituted;
[0105] R is a substituent at any position on B; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by one or more non-adjacent heteroatoms; or two adjacent R are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring;
[0106] B is an optionally substituted ring, which may be aromatic or nonaromatic, and may be monocyclic or fused with a single or multiple ring, wherein said single or multiple ring may optionally contain one or more heteroatoms;
[0107] n is 1-6;
[0108] or a compound having formula (2A) or (4A):
[0000]
[0109] wherein n, V, Z, X, W, B and R are as defined in formula (1), comprising:
contacting a compound having formula (6A), (6B) or (6C)
[0000]
wherein each L and L 1 is a leaving group; and A, V, and Z are as defined in formula (1);
with a compound having formula (7) and tautomers thereof
[0000]
wherein n, X, B and R are as defined in formula (1); and
[0114] W is OR 6 wherein R 6 is a C 1-10 alkyl; or W is NR 2 R 1 , wherein R 1 and R 2 are as defined in formula (1);
[0115] wherein said compound having formula (6A), (6B) or (6C) is contacted with said compound having formula (7) and tautomers thereof in the presence of a base to produce a compound having formula (1), and optionally hydrolyzing said compound of formula (1).
[0116] In another aspect, the present invention provides methods for preparing a compound having formula (8)
[0000]
[0117] wherein V, A, Z, and Y when attached to C are independently H, halo, azido, R 2 , CH 2 R 2 , SR 2 , OR 2 , NR 1 R 2 ; or absent when attached to N;
[0118] T 1 , T 2 , T 3 , and T 4 are independently C, N or S;
[0119] W is NR 1 R 2 or OR 6 , wherein R 6 is a C 1-10 alkyl;
[0120] X is O, S, CR 1 or NR 1 ;
[0121] E together with N and X form a ring, which may be fused with a single or multiple ring, wherein the single or multiple ring optionally contains one or more heteroatoms;
[0122] n is 1-6;
[0123] p is 0-1;
[0124] each R 1 is H or a C 1-6 alkyl;
[0125] each R 2 is H, or a C 1-10 alkyl or C 2-10 alkenyl each optionally substituted with a halogen, one or more non-adjacent heteroatoms, a carbocyclic ring, a heterocyclic ring, an aryl or heteroaryl, wherein each ring is optionally substituted;
[0126] R 5 is a substituent at any position on E; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by one or more non-adjacent heteroatoms; or two adjacent R 5 are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring;
[0127] comprising contacting a compound having a formula (9) with a compound having formula (10) and tautomers thereof:
[0000]
[0128] wherein n, V, A, Z, Y, T 1 , T 2 , T 3 , T 4 , X, W, E and R 5 are as defined in formula (8); and
[0129] each L and L 1 is a leaving group.
[0130] In the above methods, the reagents in the presence of a base and coordinating atom, such as the coordinating atom of a Lewis acid. Although the mechanism is not necessary to practice the invention, the use of a co-ordinating metal or acid allows the hydrogen on the α-carbon in formula (7) and (10) to become more acidic, thus facilitating its removal by a weak base (in this case a trialkylamine base). Hence the anion (reactive intermediate) can be generated under more mild conditions and reacted with the other reactant. The coordinating metal then orientates (holds) the resulting products in a conformation which facilitates the second bond formation allowing it to occur under milder conditions. In this step, again the remaining hydrogen on the α-carbon is rendered more acidic, and the molecule is in a conformation in which the reactive atoms are held more closely together, helping overcome entropic barriers.
[0131] The compounds of the present invention having formula (1), (2A), (2B), (4), (4A), (4B), (5A), (5B), (8), (11), (12A), (12B) and 13-15 are reproduced below:
[0000]
[0132] wherein each substituent is as defined above.
[0133] In the above formula (4), X may be NR 1 ;
[0134] A and V may independently be H or halo;
[0135] Z may be an optionally substituted carbocyclic ring, heterocyclic ring, aryl, or heteroaryl; and R may be a substituent at any position on the fused ring; and is H, OR 2 , cyano, halo, or an inorganic substituent; or C 1-6 alkyl, C 2-6 alkenyl, C 3-7 cycloalkyl, each optionally substituted by halo, ═O or one or more heteroatoms.
[0136] In the above formula (4), Z may be a 5-6 membered heterocyclic ring containing N, O, or S, and optionally substituted with halo, alkyl, alkoxy, or acetyl.
[0137] In each of the above formula, ring B in formula (1), (2A), (2B), (4A), (7) or (8), or ring E in formula (11), (12A) and (12B) may be selected from the group consisting of:
[0000]
[0138] wherein each Q, Q 1 , Q 2 , and Q 3 is independently CH or N;
[0139] Y is independently O, CH, C═O or NR 1 ;
[0140] R 1 is as defined in formula (1); and
[0141] R 5 is a substituent at any position on ring B or E; and is H, OR 2 , amino, alkoxy, amido, halogen, cyano or an inorganic substituent; or R is C 1-6 alkyl, C 2-6 alkenyl, —CONHR 1 , each optionally substituted by one or more non-adjacent heteroatoms; or two adjacent R 5 are linked to obtain a 5-6 membered optionally substituted carbocyclic or heterocyclic ring, optionally fused to an additional optionally substituted carbocyclic or heterocyclic ring.
[0142] In one embodiment, B or E is an optionally substituted phenyl. In particular examples, each R 5 in each of the above formula is H or halo.
[0143] In each of the above formula, one of A (if present) or V may be H or halo. In particular examples, one of A or V may be H or fluoro.
[0144] In each of the above formula, Z may be H, halo, or SR 2 , wherein R 2 is a C 1-10 alkyl or C 2-10 alkenyl optionally substituted with a heteroatom, a carbocyclic ring, a heterocyclic ring, an aryl or a heteroaryl. In one example, R 2 is a C 1-10 alkyl.
[0145] In each of the above formula, X may be NR 1 or S.
[0146] In some embodiments, Z, A, and V in each of the above formula may be independently H. In other embodiments, two of A, Z and V are H, and sometimes only one of A, Z and V is H. In certain embodiments, only one of A, Z and V is a halogen (e.g., fluorine), and sometimes two of A, Z and V are halogen. In other embodiments, Z, A and V in each of the above formula is SR 2 , which may be oxidized to SO 2 R, which can readily be replaced with another nucleophile, such as OR or an amino group.
[0147] In some embodiments, W is OR 6 group, which may be replaced with a —R 7 R 8 —(CH 2 ) n —CHR 2 —NR 3 R 4 , wherein R 7 is N or CR 1 wherein R 1 is H or C 1-6 alkyl; R 8 is H or C 1-10 alkyl, and wherein in the —CHR 2 —NR 3 R 4 moiety, one of R 3 or R 4 together with the C may form an optionally substituted heterocyclic or heteroaryl ring, or wherein in the —CHR 2 —NR 3 R 4 moiety each R 3 or R 4 together with the N may form an optionally substituted carbocyclic, heterocyclic, aryl or heteroaryl ring. In some embodiment, W is not NH 2 .
[0148] In each of the above formula, one, two, three or all of V, Z, and A (if present) may independently be selected from a NR 1 R 2 moiety, wherein R 1 is H, and R 2 is a C 1-10 alkyl optionally substituted with a heteroatom, a C 3-6 cycloalkyl, aryl or a 5-14 membered heterocyclic ring containing one or more N, O, or S. In some embodiments, W is a NR 1 R 2 moiety and one of A or Z is the same or a different NR 1 R 2 moiety compared to W. If more than one NR 1 R 2 moiety is present in a compound within the invention, as when both A and W are NR 1 R 2 in a compound according to formula (1), for example, each R 1 and each R 2 are independently selected.
[0149] In one example, R 2 is a C 1-10 alkyl substituted with an optionally substituted 5-14 membered heterocyclic ring. For example, R 2 may be a C 1-10 alkyl substituted with morpholine, thiomorpholine, imidazole, aminothiadiazole, pyrrolidine, piperazine, pyridine or piperidine. Alternatively, R 1 and R 2 together with N may form an optionally substituted heterocyclic ring containing one or more N, O, or S. For example, R 1 and R 2 together with N may form piperidine, pyrrolidine, piperazine, morpholine, thiomorpholine, imidazole, or aminothiadiazole.
[0150] Illustrative examples of optionally substituted heterocyclic rings include but are not limited to tetrahydrofuran, 1,3-dioxolane, 2,3-dihydrofuran, tetrahydropyran, benzofuran, isobenzofuran, 1,3-dihydro-isobenzofuran, isoxazole, 4,5-dihydroisoxazole, piperidine, pyrrolidine, pyrrolidin-2-one, pyrrole, pyridine, pyrimidine, octahydro-pyrrolo[3,4-b]pyridine, piperazine, pyrazine, morpholine, thiomorpholine, imidazole, aminothiadiazole, imidazolidine-2,4-dione, benzimidazole, 1,3-dihydrobenzimidazol-2-one, indole, thiazole, benzothiazole, thiadiazole, thiophene, tetrahydro-thiophene 1,1-dioxide, diazepine, triazole, diazabicyclo[2.2.1]heptane, 2,5-diazabicyclo[2.2.1]heptane, and 2,3,4,4a,9,9a-hexahydro-1H-β-carboline.
[0151] In each of the above formula, each optionally substituted moiety may be substituted with one or more halo, OR 2 , NR 1 R 2 , carbamate, C 1-10 alkyl, C 2-10 alkenyl, each optionally substituted by halo, C═O, aryl or one or more heteroatoms; inorganic substituents, aryl, carbocyclic or a heterocyclic ring.
[0152] The compounds of the present invention may be chiral. As used herein, a chiral compound is a compound that is different from its mirror image, and has an enantiomer. Furthermore, the compounds may be racemic, or an isolated enantiomer or stereoisomer. Methods of synthesizing chiral compounds and resolving a racemic mixture of enantiomers are well known to those skilled in the art. See, e.g., March, “ Advanced Organic Chemistry,” John Wiley and Sons, Inc., New York, (1985), which is incorporated herein by reference.
[0153] Illustrative examples of compounds which may be prepared using the methods of the invention are shown in Table 1, and in the Examples. The present invention also encompasses other compounds having any one of the formula (1), (2), (2A), (2B), (4), (4A), (4B), (5A), (5B), (8), (11), (12A), (12B) and 13-15 comprising substituents V, A, Z, Y, and W independently selected from the substituents exemplified in Table 1 and in the Examples. Thus, the present invention is not limited to the specific combination of substituents described in various embodiments below.
[0000]
TABLE 1
MS
Yield:
325.3
77%
359.3(M + H) +
76%
369.3(M + H) +
62%
359.3(M + H) +
90%(2:1 mix)
411.2(M + H) +
56%
356.3(M + H) +
92%
356.4(M + H) +
90%
392.2(M + H) +
95%
372.1(M + H) +
98%
392.2(M + H) +
90%
411.3(M + H) +
76%
394.4
60%
289.2
84%
409.3
89%
377.4
68%
353.2
12%
377.3
97%
306.7
10%
381.0
68%
392.2
97%
342.2
41%
390
73%
424.1
43%
438.6
62%
374.5
45%
364.2
56%
363.2
34%
330.0
44%
313.1
29%
[0154] The compounds described herein may interact with regions of DNA that can form quadruplexes; or are useful intermediates to such compounds. Because regions of DNA that can form quadruplexes are regulators of biological processes such as oncogene transcription, modulators of quadruplex biological activity can be utilized as cancer therapeutics. Molecules that interact with regions of DNA that can form quadruplexes can exert a therapeutic effect on certain cell proliferative disorders and related conditions. Particularly, abnormally increased oncogene expression can cause cell proliferative disorders, and quadruplex structures typically down-regulate oncogene expression. Examples of oncogenes include but are not limited to MYC, HIF, VEGF, ABL, TGF, PDGFA, MYB, SPARC, HUMTEL, HER, VAV, RET, H-RAS, EGF, SRC, BCL1, BCL2, DHFR, HMGA, and other oncogenes known to one of skill in the art. Furthermore, the compounds described may induce cell death (e.g., apoptosis) and not interact with regions of DNA that can form quadruplexes; or are useful intermediates to such compounds.
[0155] Molecules that bind to regions of DNA that can form quadruplexes can exert a biological effect according to different mechanisms, which include for example, stabilizing a native quadruplex structure, inhibiting conversion of a native quadruplex to duplex DNA by blocking strand cleavage, and stabilizing a native quadruplex structure having a quadruplex-destabilizing nucleotide substitution and other sequence specific interactions. Thus, compounds that bind to regions of DNA that can form quadruplexes described herein may be administered to cells, tissues, or organisms for the purpose of down-regulating oncogene transcription and thereby treating cell proliferative disorders.
[0156] Determining whether the biological activity of native DNA that can form quadruplexes is modulated in a cell, tissue, or organism can be accomplished by monitoring quadruplex biological activity. Quadruplex forming regions of DNA biological activity may be monitored in cells, tissues, or organisms, for example, by detecting a decrease or increase of gene transcription in response to contacting the quadruplex forming DNA with a molecule. Transcription can be detected by directly observing RNA transcripts or observing polypeptides translated by transcripts, which are methods well known in the art.
[0157] Molecules that interact with quadruplex forming DNA and quadruplex forming nucleic acids can be utilized to treat many cell proliferative disorders. Cell proliferative disorders include, for example, colorectal cancers and hematopoietic neoplastic disorders (i.e., diseases involving hyperplastic/neoplastic cells of hematopoietic origin such as those arising from myeloid, lymphoid or erythroid lineages, or precursor cells thereof). The diseases can arise from poorly differentiated acute leukemias, e.g., erythroblastic leukemia and acute megakaryoblastic leukemia. Additional myeloid disorders include, but are not limited to, acute promyeloid leukemia (APML), acute myelogenous leukemia (AML) and chronic myelogenous leukemia (CML) (Vaickus, Crit. Rev. in Oncol./Hemotol. 11:267-297 (1991)). Lymphoid malignancies include, but are not limited to acute lymphoblastic leukemia (ALL), which includes B-lineage ALL and T-lineage ALL, chronic lymphocytic leukemia (CLL), prolymphocytic leukemia (PLL), hairy cell leukemia (HLL) and Waldenstrom's macroglobulinemia (WM). Additional forms of malignant lymphomas include, but are not limited to non-Hodgkin lymphoma and variants thereof, peripheral T cell lymphomas, adult T cell leukemia/lymphoma (ATL), cutaneous T-cell lymphoma (CTCL), large granular lymphocytic leukemia (LGF), Hodgkin's disease and Reed-Sternberg disease. Cell proliferative disorders also include cancers of the colorectum, breast, lung, liver, pancreas, lymph node, colon, prostate, brain, head and neck, skin, liver, kidney, and heart. Compounds that interact with regions of DNA that may form quadruplexes also can be utilized to target cancer related processes and conditions, such as increased angiogenesis, by inhibiting angiogenesis in a subject.
[0158] Compounds that interact with quadruplex forming regions of DNA can also be used to reduce a microbial infection, such as a viral infection. Retroviruses offer a wealth of potential targets for G-quadruplex targeted therapeutics. G-quadruplex structures have been implicated as functional elements in at least two secondary structures formed by either viral RNA or DNA in HIV, the dimer linker structure (DLS) and the central DNA flap (CDF). Additionally, DNA aptamers which are able to adopt either inter- or intramolecular quadruplex structures are able to inhibit viral replication. In one example, DNA aptamers are able to inhibit viral replication by targeting the envelope glycoprotein (putatively). In another example, DNA aptamers inhibit viral replication by targeting the HIV-integrase respectively, suggesting the involvement of native quadruplex structures in interaction with the integrase enzyme.
[0159] Dimer linker structures, which are common to all retroviruses, serve to bind two copies of the viral genome together by a non-covalent interaction between the two 5′ ends of the two viral RNA sequences. The genomic dimer is stably associated with the gag protein in the mature virus particle. In the case of HIV, the origin of this non-covalent binding may be traced to a 98 base-pair sequence containing several runs of at least two consecutive guanines (e.g., the 3′ for the formation of RNA dimers in vitro). An observed cation (potassium) dependence for the formation and stability of the dimer in vitro, in addition to the failure of an antisense sequence to effectively dimerize, has revealed the most likely binding structure to be an intermolecular G-quadruplex.
[0160] Prior to integration into the host genome, reverse transcribed viral DNA forms a pre-integration complex (PIC) with at least two major viral proteins, integrase and reverse transcriptase, which is subsequently transported into the nucleus. The Central DNA Flap (CDF) refers to 99-base length single-stranded tail of the + strand, occurring near the center of the viral duplex DNA, which is known to a play a role in the nuclear import of the PIC. Oligonucleotide mimics of CDF are known to form intermolecular G-quadruplex structures in cell-free systems.
[0161] Thus, compounds that recognize quadruplex forming regions can be used to stabilize the dimer linker structure and thus prevent de-coupling of the two RNA strands. Also, by binding to the quadruplex structure formed by the CDF, protein recognition and/or binding events for nuclear transport of the PIC may be disrupted. In either case, a substantial advantage can exist over other anti-viral therapeutics. Current Highly Active Anti-Retroviral Therapeutic (HAART) regimes rely on the use of combinations of drugs targeted towards the HIV protease and HIV integrase. The requirement for multi-drug regimes is to minimize the emergence of resistance, which will usually develop rapidly when agents are used in isolation. The source of such rapid resistance is the infidelity of the reverse transcriptase enzyme which makes a mutation approximately once in every 10,000 base pairs. An advantage of targeting viral quadruplex structures over protein targets, is that the development of resistance is slow or is impossible. A point mutation of the target quadruplex can compromise the integrity of the quadruplex structure and lead to a non-functional copy of the virus. A single therapeutic agent based on this concept may replace the multiple drug regimes currently employed, with the concomitant benefits of reduced costs and the elimination of harmful drug/drug interactions.
[0162] The following examples are offered to illustrate but not to limit the invention.
EXAMPLE 1
[0163]
[0164] Ethyl 2-(benzothiazol-2-yl)acetate was prepared by the method of Abbotto, Bradamante et. al. (J. Org. Chem. 2002, 16, 5753). A neat mixture of 2-aminothiophenol (6.94 g, 50 mmol) and ethyl cyanoacetate (5.65 g, 50 mmol) was heated at 120° C. for 3 hours at which time TLC analysis indicated that the reaction was complete as judged by the disappearance of starting material. The dark orange mixture was diluted with ethyl acetate/hexanes and purified by flash chromatography using 10-20% ethyl acetate/hexanes (Rf=0.35, 10% ethyl acetate/hexanes) as an eluant. After concentration by rotary evaporator, ethyl 2-(benzothiazol-2-yl)acetate could be obtained as a yellow oil in 72% yield (7.97 g).
[0165] LCMS: 222.3 (M+H) + .
[0000]
[0166] 2,6-dichloropicolinic acid (2.70 g, 11 mmol) was suspended in dichloromethane (10 mL) and treated with oxalyl chloride (1.74 g, 14 mmol). The mixture was cooled in an ice bath and 2 drops of dimethylformamide was added. After an initial vigorous outgassing, the ice bath was removed and the solution was stirred for 18 hours at room temperature. An aliquot was quenched with methanol and analyzed by LCMS indicating that all the acid had been converted to the acid chloride. The solution was concentrated on a rotary evaporator to give the acid chloride as a light brown crystalline solid which was used in the subsequent step without further purification. LCMS: 206.2 (methyl ester M+H) + .
[0000]
[0167] Tetrahydrofuran (25 mL) was added to a mixture of ethyl 2-(benzothiazol-2-yl)acetate, magnesium chloride (2.21 g, 10 mmol) and 2,6-dichloropicolinyl chloride (11 mmol). The resulting suspension was cooled in an ice bath and triethylamine (2.02 g, 20 mmol) was added dropwise at such a rate that the internal temperature did not go over 10° C. as measured with an internal thermocouple probe. Once the addition was complete, the ice bath was removed and the mixture was allowed to stir while warming to room temperature. Although certain adducts require additional heat and/or base to produce the cyclization, this example with 2,6-dichloropicolinic acid chloride cyclized spontaneously such that after 5 hours of stirring at room temperature, compound A could be isolated by diluting the reaction mixture with water, extraction with dichloromethane (2×150 ml) and drying the resulting organic phase with sodium sulfate. Purification by trituration with diethyl ether yielded 2.71 g (76% based on ethyl 2-(benzothiazol-2-yl)acetate) as fluffy beige crystals. 1 HNMR (CDCl 3 , 400 MHz) 9.55 (1H, d, 8.4 Hz), 8.86 (1H, d, 8.4 Hz), 7.77 (1H, dd, 7.6, 1.2 Hz), 7.61 (1H, m), 7.56 (1H, d, 8.4 Hz), 7.49 (1H, m), 4.53 (2H, q, 7.2 Hz), 1.50 (3H, t, 7.2 Hz) 13 CNMR (CDCl 3 , 100 MHz) 171.1, 167.4, 163.1, 152.9, 148.4, 140.5, 137.7, 128.5, 127.8, 126.6, 123.1, 122.1, 121.7, 120.5, 106.3, 62.0, 14.7 LCMS: 359.3 (M+H) + .
[0168] It is understood that the foregoing detailed description and accompanying examples are merely illustrative, and are not to be taken as limitations upon the scope of the invention. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications, including without limitation those relating to the chemical structures, substituents, derivatives, intermediates, syntheses, formulations and/or methods of use of the invention, may be made without departing from the spirit and scope thereof. U.S. patents and publications referenced herein are incorporated by reference.
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The present invention relates to the preparation of compounds which are capable of inducing cell death such as apoptotic cell death (apoptosis), and/or for reducing a cell proliferative disorder.
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FIELD OF THE INVENTION
The present invention relates to novel compounds that are useful in pharmaceutical applications for inhibiting the function of proteins. More specifically, the present invention relates to inhibitors of both of matrix metalloproteinase and tumor necrosis factor.
DESCRIPTION OF RELATED ART
Matrix metalloproteinases (MMPs) is constituted of at least 28 zinc-containing proteolytic enzymes that play an integral role in the physiology of the extracellular matrix (ECM). MMPs play a major role in the degradation of basement membrane and the remodeling of ECM. Certain normal physiological processes such as fetal development, inflammatory cell migration, wound healing and angiogenesis depend on the regulated activity of MMPs and natural tissue inhibitors of metalloproteinases (TIMPs). In pathological processes, such as the development of cancer, tissue-specific MMPs may be recruited to permit primary tumor growth and then the development of metastatic diseases. Activation of these MMPs has been implicated in tissue invasiveness, metastases and angiogenesis. Thus, MMP inhibition offers novel and alternative therapy to current treatment for many different types of cancer (Johnson, L. J., Dyer, R., and Hupe, D. J. Matrix Metalloproteinases. Current Opinion in Chemical Biology; 1998.2: 466-471 (1998)).
There are three distinct classes of MMPs divided by their target: collagenases (MMP-1, MMP-8, and MMP-13), stromelysins (MMP-3, MMP-10, MMP-11), and gelatinases (MMP-2 and MMP-9). MMPs are secreted into the ECM in their proenzyme form, which requires activation by other enzymes. One class of the activators is the enzyme membrane type MMP (MT-MMP). The MT-MMPs (MMP-14, MMP-15, MMP-16, MMP-17) have a transmembrane domain and are essential in the activation of pro-MMP.
Among the MMPs as mentioned above, certain MMPs (MMP-2 and MMP-9) are correlated and their over-expression has been evaluated extensively in different kinds of tumors, such colon, gastric, head and neck, prostate, and lung cancer. For example, studies showed that in colorectal cancer, both MMP-2 and MMP-9 (in both their proenzyme and active forms) were over-expressed in cancerous tissue when compared with the normal mucosa. Similar findings had been shown in gastric cancer and pancreatic cancer (Gress T. M., Muller-Pillasch F., Lerch, M. M., et al. Expressioin and in-situ localization of genes coding for extracellular matrix proteins and extracellular matrix degrading proteases in pancreatic cancer. Int. J. Cancer 1995, 62:407-413; Normura H, Sato H. Seiki M. et al. Expression of membrane type-matrix metalloproteinase in human gastric cancinomas. Cancer Res 1995; 55:3263-3266; Parsons S L, Watson S A, Brown P D, et al. Matrix metalloproteinases. Br. J. Surg. 1997, 87: 160-166). Over-expression of MMP-2 and MMP-9 was also correlated with tumor stage, tumor aggressiveness and poor prognosis for gastrointestinal, cervical, bladder and lung tumors (Nuovo G J, MacConnell P B, Simisir A, et al. Correlation of the in situ detection of polymerase chain reaction-amplified metalloproteinase complementary DNA and their inhibitors with prognosis in cervical carcinoma., Cancer Res. 1995, 55: 267-275; Davies B, Wasman J, Wasan H, et al.). Levels of matrix metalloproteinases in bladder cancer were correlated with tumor grade and invasion ( Cancer Res. 1993, 53: 5365-5369; Brown P D, Bloxidge R E, Stuart N S, et al.). Association between expression of activated 72-kilodalton gelatinase and tumor spread in non-small cell lung carcinoma existed ( J. Natl. Cancer Inst. 1993, 85: 574-578). Although there was clear over-expression of MMP in certain tumors, there was variability of over-expression of MMP in different tumor types. For example, Fieberg, et al. studied expression patterns of MMP-2, MMP-3, and MMP-7 in 47 human tumor xenografts, the result of which showed variable degrees of MMP-2 over-expression with 100% of soft tissue sarcomas, 84% of melanomas, 53% of testicular carcinoma and 26% of bladder cancers that exhibited MMP-2 over-expression (Fieberg H, Klostermeyer A, Schuler J B). Characterization of matrix metalloproteinases in 47 human tumor xenografts who exhibited a high expression level of MMP2 in melanomas and sarcomas (Abstract No. 3058, Proceedings of the 90 th Annual Meeting of the American Association for Cancer Research. Apr. 10-13, 1999 Philadelphia (Pa.)). These results suggested that MMP-2 was a reasonable therapeutic target for these tumor.
TNFα (tumor necrosis factor-α) plays an important role in the host defense. It causes resistance to many pathogenic microorganisms and some viruses. Even if TNFα has undoubtedly a beneficial function in the activation of host defense, its unregulated production (mainly on the systematic level) could lead to pathological consequences. TNFα plays a significant role in the pathogenesis of septic shock, characterized by hypotension and multiple organ failure among others. TNFα is the main mediator of cachexia characterized by abnormal weight-loss of cancer patients. Often TNFα is detected in the synovial fluid of patients suffering from arthritis. There was a broad spectrum of diseases, where TNFα could play a role. Compounds inhibiting the release of TNFα may be therefore useful in the treatment of numerous pathologies in which TNFα is involved, such as rheumatoid arthritis, Crohn's disease, plaque sclerosis, septic shock, cancer or cachexia associated with an immunodeficiency.
SUMMARY OF THE INVENTION
One objective of the present invention is to provide a compound, 1-[3,4-dihydroxy-5-(2-hydroxyethyl)-tetrahydrofuran-2-yl]pyrimidine-2,4(1H,3H)-dione, which exhibits an inhibitory effect on matrix metalloproteinase-2 (gelatinase A) and on the binding of TNFα to TNFα-RI.
Another objective of the present invention is to provide a compound having a general formula (I) for inhibiting gelatinase A
wherein X is a Zn(II) chelating group and selected from the group consisting of (CH 2 ) n OH, (CH 2 ) n NH 2 , (CH 2 ) n SH, (CH 2 ) m COOH, (CH 2 ) m COOR, (CH 2 ) m CONH 2 , (CH 2 ) m″ CONH—OH, (CH 2 ) m″ CONH—R, and (CH 2 ) n′ O(PO 3 ) m″ (m″+1) , wherein n=2, 3, 4, or 5, n′=2 or 3, m=1, 2, 3, or 4, m′=1, 2, 3, 4, 5, or 6, m″=1, 2, 3, and R=—C m′ H 2m′+1 or aryl groups.
It should be understood that both the foregoing general description and the following detailed description are intended to provide an explanation of the invention as claimed, rather than to limit the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 shows MMP-2 samples analyzed for gelatin degradation activity by zymography stained with Commassie Brilliant Blue R-250.
FIG. 2 shows hydrolysis of BG by increasing concentration of the purified MMP-2.
FIG. 3A is a chromatogram of the crude methanol extract of Taraxacum mongolicum on a TSK Gel ODS 80™ (TOSOH) reverse phase column (25 cm×4.6 mm) filled with 5 μm gel.
FIG. 3B shows a chromatogram of 1-[3,4-dihydroxy-5-(2-hydroxyethyl)tetrahydrofuran-2-yl]pyrimidine-2,4(1H,3H)-dione (Compound 1, 1.5 μg) purified from methanolic extract of Taraxacum mongolicum on a TSK Gel ODS 80™ (TOSOH) reverse phase column (25 cm×4.6 mm) filled with 5 μm of the gel particle.
FIG. 4 shows the inhibitory effect of Compound 1 on MMP-2 activity.
FIG. 5 shows the inhibition of invasive potential of ES-2 cells by Compound 1.
FIG. 6 shows the inhibitory effect of Compound 1 on the binding activity of biotinylated TNFα to TNFα-RI.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
MMP-2 Purification
The MMP-2 enzyme was obtained from cancer cells and then purified by using gelatin-Sephose 4B (Pharmacia). Serum-free conditioned medium from human ovarian carcinoma cells, ES-2, was concentrated 50-fold and then MMP-2 enzyme was obtained by ultrafiltration using a 30,000 MW (molecular weight) cut-off membrane (YM-30, Amicon). The affinity matrix was equilibrated with an equilibration buffer, which was composed of 50 mM Tris.HCl (pH7.6), 10 mM EDTA and 0.01% Tween 20, containing 0.5 M NaCl. After extensive washing with the equilibration buffer containing 0.5 M NaCl, the bound enzyme was eluted with the equilibration buffer containing 1 M NaCl.
In FIG. 1, a gelatin zymography of MMP-2 samples was shown. 0.1% gelatin (Type B, J. T. Baker) was mixed with a 10% polyacrylamide as described (Deryugina, E. I., Bourdon, M. A., Reisfeld, R. A., and Strongin, A., Remodeling of collagen matrix by human cancer cells requires activation and cell surface association of matrix metalloproteinase-2, Cancer Res. 58:3734-3750 (1998)) to prepare the gel for electrophoresis. MMP-2 samples were mixed with the SDS/PAGE sample buffer without a reducing agent and then subjected to electrophoretic analysis at 4-8° C. Negative staining with Commassie Brilliant Blue R-250 revealed the enzyme activity on the gel in FIG. 1 . The arrow indicated the electrophoretic mobility of active MMP-2. Molecular mass markers were indicated on the left. The amounts on the gel for lanes 1, 2, 3, and 4 were 5 ng, 2.5 ng, 1.25 ng, and 0.63 ng, respectively. The MMP-2 enzyme was then stored in aliquots containing 50% glycerol at −70° C. The MMP-2 samples were also analyzed by Western blotting (data not shown) using a specific monoclonal MMP-2 antibody (NeoMarkers).
The purified enzyme was already an active form with a molecular weight of about 64K. Therefore, an activation process such as using p-aminophenylmercuric acetate (APMA) for the MMP-2 was not required.
Biotinylation of Gelatin
Gelatin was dissolved to a concentration of 2 mg/ml in 20 mM PBS (phosphate buffer solution, pH 7.2). Biotinylation reagent, biotinamidocaproate N-hydroxysuccinimide ester (Sigma) in DMSO as stock, was added to the gelatin at the final concentration of 100 μg/ml. The mixture was incubated at room temperature for 30 min. The excess biotin ester was then exhaustively removed by dialyzing against double distilled water for 2 hours and then against PBS. The concentration of biotinylated gelatin (BG) was determined by using the BCA protein assay reagent (Bio-Rad), and the unmodified gelatin was used as a standard. BG was stored in aliquots containing 0.05% sodium azide at 4° C.
Gelatinase Assay on Microtiter Plates
The gelatinase activity of MMP-2 samples can be revealed by the procedure as described below. In the first part of the procedure, Strapavidin (SA, Sigma) of a concentration of 32 ng/ml in a 50 mM carbonate buffer (pH 9.5) was coated onto 96-well (50 μl/well) C-bottom microtiter plates at 4° C. overnight. The plates were then washed three times with TBST solution, which was composed of 50 mM Tris.HCl (pH 7.35) containing 150 mM NaCl and 0.05% Tween 20, to remove the excessive SA. Following a 2-hour blocking of the SA at 37° C. with 0.5% BSA (bovine serum albumin), the plates were extensively washed three times with TBST solution to remove the excessive BSA.
In the second part of the procedure, The MMP-2 sample was appropriately diluted in TTC solution, which was composed of 50mM Tris.HCl, 1 mM CaCl 2 , and 0.05% Triton X100 buffer (pH 7.5) and then mixed with equal volume of 400 ng/ml BG in the TTC buffer in the plates. The mixture solution of MMP-2 and BG was incubated at 37° C. for 60 minutes to allow degradation of BG by MMP-2 and binding of the degraded or intact BG to binding sites of the SA. The reaction was stopped by adding and washing the plates four times with TBST.
In the third part of the procedure, the plates were then incubated with diluted Extravidin-Peroxidase (EV-P, 1/5000 in TBST) for 60 min at 37° C. to allow binding of the EV-P to binding sites of the BG. The amount of the diluted EV-P added was 50 μl per well. After extensively washing the plates four times with TBST, the EV-P activity was revealed with 100 μl/well of TMB (3,3′,5,5′-tetramehylbenzezidine, a substrate of the EV-P) for 30 min. The reaction was quenched by adding 25 μl/well of 2 M H2SO4.
The plates were then read at 450 nm (reference length 470 nm) in a microtiter plate reader (Dynex, MRX). The absorbance at 450 nm increased as the concentration of MMP-2 increased. That is, an increase in the concentration of purified MMP-2 could result in an increase in the hydrolysis of BG, as shown in FIG. 2 . In FIG. 2, each data point represented the mean value of a triplicate measurement. The response was linear from 0.078-5 ng/ml of MMP-2 enzyme. Therefore, in the reaction of BG with MMP-2, the absorbance should be a factor 3-5 times lower than an absorbance reading of BG without MMP-2 enzyme (a gelatinase).
Screening for MMP-2 Inhibitor on Microtiter Plates
The inhibition activity of MMP-2 inhibitor can also be revealed by the same procedure as described in the section, GELATINASE ASSAY ON MICROTITER PLATES, except for the second part of the procedure.
To perform the screening for MMP-2 inhibitor screening, the inhibitor candidates were first dissolved in 10% ethanol to allow a final ethanol concentration less than 3%. In the second part of the procedure, the inhibitor candidate (20 μl) was mixed with MMP-2 (30 μl, 150 ng/ml in TTC solution) to allow incubation for 10 min at 37° C. with shaking. The diluted BG (50 μl, 400 ng/ml in TTC solution) was then added to the mixture for each well. Followed by incubation at 37° C. for another 60 min. with shaking, the reaction was stopped by adding and washing four times with TBST solution. The other parts of the procedures were the same as above.
Finding Inhibitors Of MMP-2 From Herbal Extract
The possible MMP-2 inhibitor candidates were found from herbal ingredients fractionalized by HPLC from herb extract. After the collected herbs were washed and dried, methanol was added to the weighed herb (10/1, v/w) to extract the herbal ingredients. The extraction procedure, including blending the mixture and pooling the supernatant after centrifugation at 8000 rpm for 30 minutes, was repeated two times. The supernatant was collected and concentrated with a rotatory evaporator (Heidolph, Laborota 4000) until the final volume was reduced to about 50 ml.
Then a separation procedure was performed. 100 μl of the concentrated supernatant (i.e. the herb extract) was applied to a pre-equilibrated HPLC system (Shimadu). A TSK Gel 80™ reverse phase column (TOSOH) was used for separation. The solvents used for separation were double distilled water and absolute ethanol under 0-100% gradient for 96 minutes at a flow rate of 0.75 ml/min.
One-minute fractions were collected and dried using a SpeedVac (Savant). Each fraction was re-dissolved in 100 μl 10% ethanol for screening for MMP-2 inhibitors. The fraction(s) with MMP-2 inhibitor activity were then further purified by HPLC until the purity was more than 95%.
A compound having MMP-2 inhibitory activity was found in the methanol extract of Taraxacum mongolicum by using the procedures described above. In FIG. 3A, a chromatogram of the crude methanol extract of Taraxacum mongolicum was shown. The crude methanol extract of Taraxacum mongolicum was fractionated on a TSK Gel ODS 80™ (TOSOH) reverse phase column. The particle size of the gel in this column was 5 μm, and the column size was 25 cm×4.6 mm. The mobile phase used was a mixture of H2O (A) and absolute ethanol (B, Merck) at a flow rate of 0.75 ml/min. The column was sequentially eluted as follows: 0% B for the first 5 min; a linear gradient of 0-30% B for the next 55 minutes; 30-70% B for the next 20 minutes; 70-100% B for the next 35 min; 100% B for the next 10 minutes; and 100-0% B for the next 1 minute. The detection was performed at a wavelength of 254 nm with a detection sensitivity of 0.01 AUFS.
In FIG. 3B, a chromatogram of fractions, which was 1.5 μg, with MMP-2 inhibitor activity purified from methanol extract of Taraxacum mongolicum was shown. The fractions with MMP-2 inhibitor activity were purified on a TSK Gel ODS 80™ (TOSOH) reverse phase column. The particle size of the gel in this column was 5 μm, and the column size was 25 cm×4.6 mm. The mobile phase used was a mixture of H 2 O (A) and absolute ethanol (B,Merck) at a flow rate of 0.75 ml/min. The column was sequentially eluted by a linear gradient of 0-2% B for 12 minutes, 2-100% B for the next 8 minutes, 100% B for the next 5 minutes, and 100-0% B for the next 1 minute. The elution curve of the fractions with MMP-2 inhibitor activity is shown as Curve A, whereas the column eluted by the same blanket eluent is shown as Curve B. The detection was performed at a wavelength of 260 nm with a detection sensitivity of 0.01 AUFS.
The purified active MMP-2 inhibitor was identified as 1-[3,4-dihydroxy-5-(2-hydroxyethyl) tetrahydrofuran-2-yl]pyrimidine-2,4(1H,3H)-dione (which is abbreviated as Compound 1 in other descriptions of this specification) by mass spectrometry (Finnigan Trace MS), FT-IR (Shimadzu, FTIR-8400), ID NMR (Bruker 300 MHz, 13 C NMR δ(ppm)=166.2(C-7), 152.4(C-9), 142.7(C-11), 102.6(C-10), 90.6(C-5), 86.3(C-2), 75.7(C-4), 71.3(C-3), 62.2(C-15), and 49.4(C-14); 1 H NMR δ(ppm)=8.02(1H, d, H-11), 5.90(1H, d, H-2), 5.70(1H, d, H-10), 4.18(1H, m, H-3), 4.15(1H, m, H-4), 4.00(1H, m, H-5), 3.72(2H, m, H-15) and 2D NMR (Varian Inova-600 MHz), and its molecular weight was 258.
Inhibition of Compound 1 On MMP-2 Activity
The effect of Compound 1 on MMP-2 activity was measured by basically the same procedure as described in the section, GELATINASE ASSAY ON MICROTITER PLATES. As Compound 1 was similar to uridine in chemical structure, the effect of a commercial available uridine (Sigma, U-3750, D-Ribose) on MMP-2 activity was also measured for comparison in the experiment.
Briefly, the 96-well C-bottom microtiter plate was coated with strapavidin (SA) at a concentration of 32 ng/ml in 50 mM carbonate buffer (pH 9.5) at 4° C. overnight. Followed by washing 3 times with TBST, the plate was blocked with 0.5% BSA for 60 minutes at 37° C.
Compound 1 dissolved in H 2 O was diluted with TTC to 1 mM. The Compound 1 solution was then further serially diluted to different concentrations. MMP-2 was then added to the Compound 1 solution with different concentrations at a concentration of 0.6 ng/ml by the volume ratio of 3:2. After the mixture was incubated at 37° C. for 10 minutes with shaking at 500 rpm, 50 μl of BG (400 ng/ml in TTC solution) was added to the MMP-2/Compound 1 mixture. Followed by incubation at 37° C. for another 1 hour, the mixture was then transferred into the SA coated plate at a volume of 50 μl/well. After the reaction was allowed to proceed for 1 hour, the plate was then washed 4 times with TBST solution.
EV-P (1/5000 in TBST, 50 μl/well) was added to the plate and incubated at 37° C. for another 1 hour. After extensive washing 4 times with TBST, the EV-P activity was revealed with 100 μl/well of TMB for 30 min. The reaction was stopped by adding 25 μl/well of 2 M H 2 SO 4 . The plates were then read at 450 nm (reference length 470 nm) in a microtiter plate reader (Dynex, MRX).
The result revealed that Compound 1 caused a dose response inhibition on MMP-2 activity as shown in FIG. 4 . In particular, the 50% inhibitory dose (IC50) calculated was 150 μM. However, uridine showed no inhibitory activity to MMP-2 at the concentration of 0.82 mM (data not shown).
Cancer Cell Lines Used for Proliferation/Cytotoxicity Assay
Five cancer-derived cell lines obtained from the American Type Culture Collection (ATCC) were used for the following proliferation/cytotoxicity assay. These cell lines are listed as follow:
ES-2 is a human ovarian carcinoma. It was maintained in a modified McCoy's 5A medium (Gibco) and supplemented with 10% FBS (fetal bovine serum).
COLO205 is a human colon cancer-derived cell line. It was maintained in a RPMI 1640 medium (Hyclone), and supplemented with 10% heat-inactivated FBS.
PC-3 is a human prostate cancer-derived cell line. It was maintained in a Ham's F12 K medium (Gibco) and supplemented with 7% FBS.
A375 is a human malignant melanoma-derived cell line. It was maintained in a Dulbecco's modified Eagle's medium (DMEM, Hyclone) and supplemented with 10% FBS, 4 mM L-glutamine, 4.5 g/l glucose, and 1.0 mM sodium pyruvate.
A549 is a human lung cancer-derived cell line. It was maintained in a F12K medium (Gibco) and supplemented with 10% FBS.
Effect of Compound 1 on Cancer Cell Proliferation In Vitro
To determine the cytotoxicity of Compound 1 or uridine on each cancer cell lines, ES-2, COLO205, PC-3, A375, and A549 cell lines were used. Each cancer cell line at a concentration of 1×10 4 cells/100 μl in each well (Falcon, MicroTest™ 96) was exposed to Compound 1, uridine or 1 μM paclitaxel (taxol, Sigma) for 72 hours in a complete medium. The Compound 1 and uridine were serially two-fold diluted from the concentration of 0.258 mg/ml.
Cellular viability was estimated by the tetrazolium dye reduction assay (XTT assay, Boehringer Mannheim). The amount of XTT reagent (a tetrazolium salt) added to the bottom wells was 100 μl/well and its concentration was 1 mg/ml. The-wells were incubated for 4 hours to allow viable cells to develop color. Absorbance (O.D.) was measured at 450 nm with the reference wavelength at 690 nm.
Due to the aggressive proliferation capacity of cancer cells, it was assumed that viable cells were actively proliferating. It was found that Compound 1 and uridine did not reduce cellular viability. Hence, Compound 1 and uridine did not inhibit cell proliferation in vivo (data not shown). However, inhibition of cell proliferation was proportional to the concentration of paclitaxel, but varied from cell line to cell line.
Effect of Compound 1 on Invasive/Metastatic Potential of Cancer Cells
In this method, Boyden chemotaxis assay chambers (Costar Transwell plates) were used. Each Boyden chemotaxis assay chamber included a top chamber having a filter as the bottom side of the top chamber and a bottom well surrounding the top chamber. The bottom side of the top chamber used here was an 8 μm-pore polycarbonate filter.
0.35 ml of a medium with complete nutrition supplements as a chemo-attractant was added to each bottom well. Cancer cells (2×10 5 in 50 μl) were then plated on the filters in each of the top chambers. Compound 1 or uridine was diluted in the serum-free medium to 0.536 mg/ml and then was added to the top chambers, with the volume of 50 μl/chamber. The control tests were performed with 2 μM paclitaxel (positive control) or with medium only (negative control) in the top chambers.
After an 18-hour incubation, the cells in the top chambers were carefully emptied with sterile cotton buds. 100 μl XTT reagent (1 mg/ml) was added to each of the bottom wells. After incubating for 4 hours, absorbance (O.D.) was measured at 450 nm with the reference wavelength at 690 nm. The ratio of the OD from the bottom wells to that of the OD from the bottom wells of the control tests was taken as the invasive potential. Results presented are from three different independent experiments.
The effect of Compound 1 on the invasive potential on ES-2 cell lines was shown in FIG. 5 . The ability of Compound 1 to inhibit invasive activity varied significantly from cell line to cell line. ES-2 was the most affected cell line. In particular, the 50% inhibitory dose (IC50) was 23 μg/ml (i.e. 0.09 μM). The other four cell lines were not significantly affected by Compound 1 in the same ranges as ES-2 (data not shown). As for uridine, it did not show any effect on all the five cancer cell lines in this experiment (data not shown).
Structure-Activity Relationship on Inhibiting MMP-2 of Compound 1
Peter D, Brown et al. and G. Clemens et al. have discussed about the structure-activity relationships of several matrix metaloproteinase inhibitors (MMPIs) such as hydroxamic acid and 4-biphenoyl propionic acid (Clendeninn, NJ and Appelt K (2001) Matrix Metallopoteinase inhibtiors in Cancer Therapy. Humana Press Inc. NJ) (Chapter 5. pp.113-142; Chapter 7, pp.175-192). The requirements for a molecule to be an effective inhibitor of the MMPs are a functional group (e.g., carboxylic acid, hydroxamic acid, and sulfhydryl, etc.) capable of chelating the zinc (II) ion of the active site, at least one functional group which provides a hydrogen bond interaction with the enzyme back-bone and one or more side chains which undergo effective Van der Waals interactions with the enzyme subsites.
Comparing the structure of Compound 1 with the requirements described above, it was shown that the hydroxy group on the hydroxyethyl part of Compound 1 should be responsible for the chelating of the Zn (II) ion in the active site of MMP-2 enzyme. The pyrimidine part of Compound 1 can offer Van der Waals interaction with the enzyme subsites, and the oxygen and nitrogen atoms of compound 1 can form hydrogen-bondings to the MMP-2's peptide back-bone.
Therefore, it is reasonable to replace the hydroxyethyl (CH 2 CH 2 OH) part of Compound 1 to other functional groups capable of chelating Zn (II) ion in the active site of the MMP-2 enzyme. The other chelating functional groups can be, for example, (CH 2 ) n OH, (CH 2 ) n NH 2 , (CH 2 ) n SH, (CH 2 ) m COOH, (CH 2 ) m COOR, (CH 2 ) m CONH 2 , (CH 2 ) m″ CONH—OH, (CH 2 ) m″ CONH—R, and (CH 2 ) n′ O(PO 3 ) m″ (m ″+1) , wherein n=2,3,4, or 5, n′=2 or 3, m=1, 2, 3, or 4, m′=1, 2, 3, 4, 5, or 6, m″=1, 2, 3, and R=—C m′ H 2m′+1 or aryl groups.
Inhibitory Effect of Compound 1 on TNFα Binding To TNFα-RI
50 μl TNFα-RI at a concentration of 0.25 μg/ml was coated onto each well of a 96-well C-bottom microtiter plate (Nunc) in a 50 mM carbonate buffer (pH 9.5) at 4° C. overnight. The plate was washed 3 times with 200 μl TBST solution composed of 50 mM Tris.HCl (pH 7.35) containing 0.15 M NaCl and 0.05% Tween 20 to remove excess TNFα-RI. 200 μl/well of 0.5% BSA in PBS was added to each plate for blocking of the TNFα-RI. The reaction was carried out at 37° C. for 2 hours followed by washing 4 times with TBST to remove excess BSA.
Compound 1 was serially diluted in TBST solution. Biotinylated TNFα with a concentration of 0.5 μg/ml was mixed with Compound 1 solution in a volume ratio of 1:1. The reaction was allowed to proceed for 30 minutes at 37° C. with shaking at 500 rpm for allowing mixing. The mixtures were then added to the TNFα-RI coated plate, 50 μl for each well. The plate was then incubated at 37° C. for 2 hours with shaking again at 500 rpm, for competitive binding of the biotinylated TNFα and Compound 1.
Followed by washing 4 times with TBST, Extravidin-alkaline phosphatase (Sigma) diluted in TBST (1/5,000) was added to the plate, 50 μl/well. The plate was further incubated at 37° C. for 2 hours and then washed 4 times with TBST. A substrate of alkaline phosphatase, p-nitrophenyl phosphate, at a concentration of 1 mg/ml in 50 mM carbonate buffer (pH 9.5) containing 5 mM MgCl 2 was added to the plate, 50 μl/well. After a 30-minute incubation at room temperature, absorbance at the wavelength of 405 nm was measured. Suramin, a known inhibitor of TNFα binding to TNFα-RI, was used as a control and comparative compound in this experiment.
FIG. 6 shows the inhibitory effect of Compound 1 on the binding activity of biotinylated TNFα to TNFα-RI. Each data point represented the mean value of a triplicate measurement. Suramin was used for comparison in the experiment. The result in FIG. 6 showed that the inhibition percentage was increased as the compound 1 concentration increases, although the inhibition activity is smaller than that of Suramin. Therefore, compound 1 has an inhibitory activity on TNFα binding to TNFα-RI. The 50% inhibitory dose (IC50) was 50 μM.
As discussion above, Compound 1 has an inhibitory effect on MMP-2 and on the binding of TNFα to TNFα-RI. The derivatives of Compound 1, as discussed in the section, STRUCTURE-ACTIVITY RELATIONSHIP OF INHIBITING MMP-2 BY COMPOUND 1, also have an inhibitory effect on MMP-2.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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The invention discloses methods of treatment and prevention for TNFα-related disorders and MMP-related disorders and compounds useful in such treatments. In particular, the invention dislcoses pharmaceutical compositions comprising a compound of the general formula:
wherein X is a Zn(II) chelating group and selected from the group consisting of (CH 2 ) n OH, (CH 2 ) n NH 2 , (CH 2 ) n SH, (CH 2 ) m COOH, (CH 2 ) m COOR, (CH 2 ) m CONH 2 , (CH 2 ) m″ CONH—OH, (CH 2 ) m″ CONH—R, and (CH2) n′ O(PO 3 ) m″ (m″+1) , wherein n=2, 3, 4, or 5, n′=2 or 3, m=1, 2, 3, or 4, m′=1, 2, 3, 4, 5, or 6, m″=1, 2, 3, and R=—C m′ , H 2m′+1 or aryl groups, especially 1-[3,4-dihydroxy-5-(2-hydroxyethyl)-tetrahydrofuran-2-yl]pyrimidine-2,4(1H,3H)-dione, which has an inhibitory effect on matrix metalloproteinase-2 (gelatinase A) and on the binding of TNFα to TNFα-RI.
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FIELD OF THE INVENTION
This invention relates to discs for cleaners of liquid-containing vessels and more particularly to automatic pool cleaners having fluted discs for improved performance in swimming pools.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,351,077 to Hofmann and U.S. Pat. No. 4,642,833 to Stoltz, et al., incorporated herein in their entireties by this reference, disclose automatic, water-interruption-type suction swimming pool cleaners having flexible annular discs. These discs are typically mounted near the inlets of the suction cleaners and designed to contact pool surfaces when in use. By doing so, the discs decrease the tendency of the cleaners to disengage from pool surfaces, particularly when the cleaners are negotiating transition regions between walls and floors.
U.S. Pat. No. 4,193,156 to Chauvier, also incorporated herein in its entirety by this reference, describes (at column 4, lines 5-55) an annular disc having numerous "concertina-like," "circumferentially spaced folds." These folds extend when their associated swimming pool cleaner encounters a transition region, purportedly "keeping the inflow of water into the mouth opening to a minimum." Other existing discs similarly are designed for improved adhesion to surfaces to be cleaned, thereby reducing fluid flow into the mouth of the cleaners.
SUMMARY OF THE INVENTION
The present invention provides alternative flexible discs for devices such as automatic swimming pool cleaners. Unlike the discs described above, the present invention incorporates one or more flutes, or curved raised areas (arched protrusions), therein. Each such flute extends generally radially from adjacent the central portion of the disc to its periphery, creating a direct fluid flow path from the periphery of the disc to the mouth of the associated cleaner. Doing so expands the cleaning area of the disc without concurrently enlarging its physical area, enhancing performance over conventional discs.
In particular, fluid flow rates into the cleaner mouth increase significantly in the fluted areas. This accelerated flow reduces the pressure (according to Bernoulli's equation) not only in the fluted areas themselves, but also beyond the periphery of the disc in the regions surrounding the openings provided by the flutes. This larger area of low pressure results in a greater area of the vessel being subject to cleaning for a given-sized disc, since the low pressure region draws debris toward the disc (the source of low pressure).
Certain embodiments of the present invention include dual flutes symmetric about a radius of the disc. Fewer or greater flutes may be included, however, consistent with the scope of the invention. Moreover, such flutes need not be of uniform width or depth, but rather may taper toward the central portion of the disc (thereby effectively funneling fluid from the periphery) and simultaneously decrease in depth. The boundaries of the flutes additionally may be either straight or curved as suitable or desired.
Additional features of the present invention include a curved, or upturned, lip between flutes. The lip, forming the leading edge of the disc, supplies an inclined surface for and sufficient rigidity to the disc to enable it to ride over various objects, including many drains, lights, valves, and nozzles, projecting from internal surfaces of pools. The disc underside also contains an integrally-formed ramped segment surrounding its (nominally circular) central aperture. This ramp likewise assists the pool cleaner in negotiating obstacles, supplying a smooth progression from the disc bottom to the bottom of the cleaner footpad (which the disc surrounds in use), which too may include a ramp.
Multiple openings through the disc enable fluid to pass from one surface of the disc to the other, maintaining a boundary fluid layer between the lower surface of the disc and the adjacent surface of the pool. These openings facilitate movement of the disc relative to the pool cleaner and allow dirt and debris to be entrained in the flow of fluid through the openings and in the boundary layer. Another embodiment of the present invention includes a multi-featured periphery and a non-circular central aperture.
It is therefore an object of the present invention to provide a disc incorporating one or more generally radial flutes extending to its periphery.
It is a further object of the present invention to provide a disc enhancing the performance of an automatic swimming pool cleaner through increasing its cleaning area by providing a larger low pressure region.
It is an additional object of the present invention to provide a disc having one or more upturned lips to facilitate negotiating obstacles.
It is yet another object of the present invention to provide a disc having an underside containing a ramped segment surrounding its central aperture.
It is, moreover, an object of the present invention to provide a disc including multiple openings therethrough, enabling fluid to pass from one surface of the disc to the other.
Other objects, features, and advantages of the present invention will become apparent with reference to the remainder of the text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a disc of the present invention.
FIG. 2 is a top plan view of the disc of FIG. 1.
FIG. 3 is a cross-sectional view of the disc of FIG. 1 taken along lines 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view of the disc of FIG. 1 taken along lines 4--4 of FIG. 2.
FIG. 5 is a cross-sectional view of the disc of FIG. 1 taken along lines 5--5 of FIG. 2.
FIG. 6 is a top plan view of an alternate embodiment of a disc of the present invention.
DETAILED DESCRIPTION
FIGS. 1-5 illustrate disc 10 of the present invention. Disc 10 defines a central aperture 14, nominally circular, in which a footpad of an automatic swimming pool cleaner may be received, for example. Disc 10 also defines a generally planar upper surface 18, a periphery 20 and, as shown in FIG. 3, a lower surface 22. Extending upward from upper surface 18 are curved raised areas (arched protrusions), or flutes 26, which effectively expand the cleaning area of disc 10 without concurrently enlarging its physical area. Each flute 26 extends generally radially from adjacent the reinforced area 28 of disc 10 surrounding central aperture 14 to periphery 20, creating a direct path from the periphery 20 to the mouth of the associated cleaner for debris-laden fluid.
FIGS. 1-3 also detail the raised lip 30 of periphery 20. Located intermediate adjacent flutes 26, lip 30 provides a ramped portion of disc 10 (which may be of increased rigidity) to facilitate the disc 10 negotiating obstacles often projecting from interior pool surfaces. Pins or stops 32, which may be integrally formed with and project upward from the reinforced area 28 of disc 10, cooperate with portions of a footpad or other component to inhibit misorientation of disc 10. In use, lip 30 forms the leading edge of disc 10 as it and associated equipment move throughout a pool or other vessel, enabling the disc 10 to ride over objects encountered therein. Openings 34 through disc 10 enable fluid to pass between upper and lower surfaces 18 and 22 of disc 10 when in use, maintaining a boundary fluid layer between the lower surface 22 of disc 10 and the adjacent surface of the pool or other structure to be cleaned.
Shown in FIGS. 3-4 is ramp 38, projecting from lower surface 22 of disc 10 and positioned concentrically about central aperture 14. Ramp 38 promotes a smooth transition between lower surface 22 and the bottom of a footpad (or other component) received by central aperture 14, facilitating unobstructed movement of a swimming pool cleaner associated with the footpad. FIG. 3 similarly discloses radius 42 existing between lip 30 and lower surface 22 of disc 10, providing a smooth transition therebetween and, as noted above, an inclined surface, or ramp, for negotiating obstacles.
In an embodiment of the invention consistent with FIGS. 1-5, flutes 26 are positioned symmetrically about a radial axis 46 extending through disc 10 from central aperture 14 to periphery 20. As shown in these figures, flutes 26 need not be of uniform width (W) or height (H), but rather may be widest and highest (i.e. protrude further) at periphery 20 and taper in width while decreasing in height toward reinforced area 28. As noted earlier, fluid flow rates into the cleaner mouth increase substantially in the fluted areas of disc 10. This accelerated flow creates a region of low pressure extending beyond periphery 20, increasing the effective cleaning area of the cleaner.
Although two flutes 26 are illustrated in FIG. 1, the number of flutes 26 is not necessarily critical to the invention. Consequently, disc 10 may include more or less than two flutes 26 as necessary or desired. Those skilled in the art will recognize, however, that including vast numbers of flutes 26 on disc 10 may ultimately diminish the effectiveness of the associated cleaner by reducing the quantity of the increased fluid flow through each to a negligible amount.
FIG. 5 details selected characteristics of a portion of flute 26 near periphery 20. Whereas upper surface 18 and lower surface 22 generally define parallel planes, at flute 26 each extends upward above the plane formed by upper surface 18. These upwardly-extending surfaces 18A and 22A, while remaining approximately parallel at any particular location, no longer are planar but rather are curved. The result is an approximately semi-conical structure for flute 26 that, as shown in FIGS. 1-2, may be truncated adjacent reinforced area 28.
FIG. 6 illustrates an alternate disc 50 of the present invention. Although including flutes 54 similar to disc 10, disc has a multi-featured periphery 58 differing in shape from periphery 20. Central aperture 62 of disc 50 additionally is configured differently than central aperture 14 of disc 10, with reinforced area 66 being more triangular than circular in nature. Defining central aperture 62 in this manner permits suitable attachment to the style of footpad 70 shown in FIG. 6. Doing so also alleviates any need for including stops 32 or other external orientation means to be present on disc 50.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those of ordinary skill in the art and may be made without departing from the scope or spirit of the invention.
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Discs for devices such as automatic swimming pool cleaners are disclosed. The discs incorporate one or more flutes, or raised areas (arched protrusions), extending generally radially from adjacent their central portions to their peripheries. The peripheries themselves, moreover, may include upturned areas (lips) between flutes, and both the discs and footpad may include ramped segments facilitating movement over obstacles extending from swimming pool surfaces.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for establishing a calibrated reference value representing a threshold and for comparing the reference value with a signal representing a variable parameter to determine the variable parameter's condition.
A wide variety of methods exist for calibrating a reference value which can be used to determine when a signal representing a variable parameter increases past a predetermined threshold. In a typical method using an electronic system, a transducer of a sensor circuit detects a variable physical parameter and produces a corresponding sensor voltage signal (or current signal) that represents the condition of the physical parameter. The sensor voltage signal is then compared with a reference voltage representing the reference value. Typically, the reference voltage is provided by an electronic calibration circuit that includes a precision potentiometer having an adjustable wiper that divides a supply voltage. The reference voltage is established by directing the physical parameter to the desired level and adjusting the potentiometer until the output voltage from the potentiometer equals the sensor voltage signal when the physical parameter is at the desired level. Typically, a comparator circuit is used to compare the reference voltage with the sensor voltage signal.
The method for setting a reference voltage described briefly above requires directing the physical parameter to assume the desired threshold. Sometimes, however, this may not be possible. For example, an accurate determination of the physical parameter may not be available or may be available only for two extreme conditions of the physical parameter. Alternatively, setting and holding the physical parameter at the threshold may be burdensome, inefficient, or otherwise uneconomical. When the physical parameter cannot be held at the threshold, then the reference voltage must be otherwise determined in order for the circuit to be able to indicate when the physical parameter has achieved the calibrated threshold.
Therefore, there is a need to develop a simple method and apparatus to accurately establish a calibrated reference voltage representing a threshold without requiring the physical parameter to be at the corresponding threshold before the reference can be calibrated. In addition, there is a need to develop a method and apparatus to monitor the physical parameter and indicate whether the threshold has been overcome.
SUMMARY OF THE INVENTION
The present invention is embodied in an apparatus, and related method, for selecting a calibrated threshold and comparing a variable parameter with the selected threshold without preliminarily requiring the parameter to be at the corresponding threshold when the threshold is selected. The apparatus includes a measuring circuit for providing a measurement signal representing the variable parameter and a calibration circuit for providing a reference value representing the threshold. The measuring circuit monitors the variable parameter and compares it with the selected threshold by comparing the measurement signal with the reference value. The variable parameter can vary in a range between a predetermined low and high value.
To calibrate the reference value, the variable parameter is caused to assume a first condition at the predetermined high value of the range, whereupon the measuring circuit provides a first signal representative of the first condition. With the variable parameter at the first condition, the calibration circuit is adjusted to provide a first calibration value equal to the first signal. The variable parameter is then caused to assume a second condition at a predetermined low value of the range, whereupon the measuring circuit provides a second signal representative of the second condition. With the variable parameter at the second condition, the calibration circuit is adjusted to provide a second calibration value equal to the second signal. The calibration circuit is then set to average the first and second calibration value to provide a reference value midway between the first and second signals that represents the selected threshold. After the reference value is set, the measuring circuit monitors the variable parameter and compares the measurement signal with the reference value to determine the condition of the variable parameter.
In a more detailed feature of the invention, the measurement signal, the first and second signals, and the reference value are voltage levels. The calibration circuit includes two potentiometers and two isolation resistors. One potentiometer has its wiper set to provide a first calibration voltage equal to the voltage of the first signal. The other potentiometer has its wiper set to provide a second calibration voltage equal to the voltage of the second signal. The isolation resistors are used to combine the first and second calibration voltages to produce a reference voltage having a value midway between the first and second calibration voltages without using an active circuit element.
The embodiment of the invention can be used, for example, in a system for measuring the level of liquid in a tank in which the variable parameter discussed above represents the level of liquid in the tank. A capacitance sensor having first and second conductors detects the level in the tank. The first conductor is a conductive plate placed on the tank wall. The tank wall at the location of the plate is insulating. The second conductor is either the liquid, if the liquid is conducting, or the ground, if the liquid is not conducting. The first condition is a full tank and the second condition is an empty tank. The selected threshold represents a liquid level in the tank which is midway between a full tank and an empty tank.
In another more detailed feature of the invention, the measuring circuit includes a threshold detection circuit that uses an oscillator and a sensor amplifier to detect the capacitance of the capacitance sensor and a comparator circuit. The capacitance sensor and the oscillator are connected to the sensor amplifier. The sensor amplifies an oscillating signal from the oscillator to provide a sensor signal, the gain of the sensor amplifier varying in proportion to the capacitance of the sensor. The sensor signal is compared with the reference voltage by the comparator circuit. The comparator circuit switches on a light emitting diode (LED) coupled to the output of the comparator circuit whenever the sensor signal is greater than the reference voltage from the calibration circuit. The LED, when switched on, significantly increases the current draw of the apparatus. This increase in current draw can be used to indicate the condition of the variable parameter.
Other features and advantages of the present invention should become apparent from the following description of the preferred embodiment, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the calibration and threshold monitoring system embodying the invention.
FIG. 2 is a schematic diagram of a power regulation circuit for supplying power to the calibration and threshold monitoring system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings and, more particularly to FIG. 1, there is shown a threshold level detection system 10 for determining whether a physical parameter has reached a threshold value. In the detection system, the physical parameter to be measured is the level of liquid 12 in a tank. Attached to the tank 14 is a capacitance sensor having a capacitor plate 16 that provides a capacitance value that varies with the level of the liquid in the tank. The capacitance value is converted into a voltage signal by a measuring circuit having an oscillator 18, a sensor amplifier 20 and a peak detector 22. A comparator 24 compares the voltage signal with a reference voltage provided by a calibration circuit 26. The output of the comparator 24 controls the state of an LED circuit 28.
The typical capacitance sensor includes two conductors separated by an insulating layer. The tank 14 is typically made of an insulating non-metallic material and forms the insulating layer of the capacitance sensor. In some embodiments, only the portion of the tank wall that has the sensor may be insulating while the rest of the tank wall is metal. Secured to the outside of the insulated tank wall in a vertical fashion is a capacitor plate 16. The capacitance plate is a conductor and forms one of the conductors of the capacitance sensor. Inside the tank 14 is a liquid 12 that if conductive, can be grounded to form the other conductor of the capacitance sensor. Alternatively, the liquid, if non-conductive, forms part of the dielectric of the capacitance sensor along with the insulating tank wall. The capacitance of the sensor increases as the liquid level in the tank increases. The change of capacitance is measured and indicated by an electronic circuit.
The inputs of the sensor amplifier 20 are coupled to the oscillator 18 and the capacitor plate 16. The sensor amplifier amplifies an oscillating signal from the oscillator with a gain that varies in proportion to the capacitance at the capacitor plate. The amplitude of the signal from the sensor amplifier is detected by the peak detector 22. A voltage from the peak detector, which represents the peak amplitude of the detected voltage signal, is compared by the comparator 24 with the calibration voltage from the calibration circuit 26. If the voltage signal from the peak detector falls below the level of the calibration voltage, the comparator causes the LED circuit 28 to indicate that the liquid level in the tank is below a midpoint threshold of the tank 14.
The calibration circuit 26 includes two variable resistors R1 and R2, two isolation resistors R3 and R4 and a three-positioned switch SW1. The variable resistors R1 and R2 preferably take the form of a potentiometer having a wiper.
The first variable resistor R1 is connected to two bias resistors R5 and R6 which maintain a certain voltage between the power supply voltage and the output voltage provided at the wiper of the first variable resistor. The first isolation resistor R3 is connected between the wiper of the first variable resistor and the output of the calibration circuit 26. The second variable resistor R2 is connected to two bias resistors R7 and R8, which maintain a certain voltage between the power supply voltage and the output voltage provided at the wiper of the second variable resistor. The second isolation resistor R4 is connected between the wiper of the second variable resistor and the output of the calibration circuit.
The isolation resistors R3 and R4 are of equal value and of a larger resistance value than the two variable resistors R1 and R2. The output of the calibration circuit 26 is coupled to a high impedance input of the comparator 24. The output voltage of the calibration circuit (the output voltage is the voltage at the connection between isolation resistors R3 and R4) is the reference voltage and is generally the average of the voltage representing an empty tank and the voltage representing a full tank voltage.
The three-position switch SW1 is coupled between the output of the calibration circuit 26 and the wipers of the first and second variable resistors R1 and R2. The middle position of the switch SW1 is the normal operating position of the switch and has no connection. The empty position of the switch is used to calibrate the voltage representing an empty tank. The full position of the switch is used to calibrate the voltage representing a full tank.
To calibrate the reference voltage, the tank 14 is emptied and the switch SW1 is set to the empty position, which bypasses resistor R3 and connects the output of the calibration circuit 26 directly to the wiper of the first variable resistor R1. The wiper of the first variable resistor R1 is then adjusted such that the voltage from the output of calibration circuit 26 is equal to the empty voltage signal present at the other input of the comparator 24.
Continuing the calibration sequence, the tank 14 is filled with liquid and switch SW1 is set to the full position, which bypasses resistor R4 and connects the output of the calibration circuit 26 directly to the wiper of the second variable resistor R2. The wiper of the second variable resistor R2 is then adjusted until the voltage at the output of the calibration circuit is equal to the full voltage signal at the other input of the comparator 24. The order of calibrating the reference voltage is not critical. Thus, the calibration sequence can first fill the tank and then empty the tank in setting the full voltage signal and the empty to voltage signal.
After the empty and full liquid level calibrations are performed, the switch SW1 is set to the middle position having no connection. The isolation resistors R3 and R4 are chosen to have a resistance such that the voltage from the wiper of variable resistor R1 and the voltage from the variable resistor R7 are combined when the switch is set to the middle position to produce at the output of the calibration circuit 26 a reference voltage that is substantially an average value midway between the first and second calibration voltages. In the preferred embodiment, the resistance value of the bias resistors R5 and R7 is 10 kilohms, the resistance value of the bias resistors R6 and R8 is 17.8 kilohms, the resistance value of the isolation resistors R3 and R4 is 100 kilohms and the resistance value of the variable resistors R1 and R2 is 10 kilohms.
The output of the oscillator 18 is connected to the non-inverting input of the operational amplifier U1 of amplifier 20. The capacitor plate 16, which capacitively senses the level of liquid 12 in the tank 14, is connected to the inverting input of the operational amplifier U1. A feedback impedance is coupled between the output of the amplifier U1 and its inverting input. The output of the operational amplifier U1 is coupled to the peak detector 22 through a coupling capacitor (not shown). The feedback impedance consists of a resistor R9 and a capacitor C1. In the preferred embodiment, the resistance value of the resistor R9 is 10 megohm and the capacitance value of the capacitor C1 is 8 picofarads.
The output of the peak detector 22 is connected through a resistor R10 to the non-inverting input of an operational amplifier U2 of the comparator 24. The operational amplifier U2 has positive feedback from its output through a resistor R11 into its noninverting input. The reference voltage from the calibration circuit 26 is fed into the inverting input of the operational amplifier U2. Therefore, when the voltage signal applied at the non-inverting input of the operational amplifier exceeds the reference voltage applied at the inverting input, the output of the operation amplifier is driven positive until the output reaches the saturation voltage of the operational amplifier. The preferred embodiment, the resistance value of resistor R10 is 33 kilohms and of resistor R11 is 15 megohms.
The output voltage of the operational amplifier U2 is coupled through a resistor R12 to the base of a transistor Q1 of the LED circuit 28. When the output of operational amplifier is positive, the transistor is switched on allowing a current to flow from the positive power source through the bias resistor R13 to turn on the light-emitting diode LED1. The preferred value of resistors R12 is 10 kilohms and R13 is 470 ohms.
With reference now to FIG. 2, a power supply 30 provides a voltage V+to the detection system 10 and provides a current signal indicating the condition of the liquid level. An unregulated supply voltage of 36 volt dc passes through a connector J1 to the power supply. A diode D1 prevents a reverse current flow. The unregulated supply voltage is applied to the input of a voltage regulator U3. Two resistors R14 and R15 bias the voltage regulator to provide a power supply voltage V+of 9 volts. In the preferred embodiment, the resistance value of the resistor R14 is 6.98 kilohms and of the resistor R15 is 1.2 kilohms. The capacitors C2 and C3 function to smooth voltage ripples. The preferred capacitance value of the capacitor C2 is 0.1 microfarads and of the capacitor C3 is 1 microfarad.
The current from the power supply 30 also functions as a threshold indication. When the light-emitting diode LED1 is off, the current draw through the power supply for all of the circuitry of the detection system 10 is approximately 4 milliamps. When the light-emitting diode LED1 is on, the current draw through the power supply increases to approximately 20 milliamps. This variation in supply current through the power supply can be used to indicate that the threshold level has been obtained without the need for an additional conversion circuit.
From the foregoing, it will be appreciated that the threshold level detection system of the preferred embodiment of the invention allows a threshold to be established without requiring a physical parameter to be preliminarily held at a level corresponding to the threshold. The system also provides a reference voltage representing the threshold by using merely passive resistive components and a three position switch. Further, the system provides a current signal indicating the condition of the physical parameter without requiring an additional voltage-to-current conversion circuit.
Although the foregoing discloses preferred embodiments of the present invention, it is understood that those skilled in the art may make various changes to the preferred embodiment shown without departing from the scope of the invention. The invention is defined only by the following claims.
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A threshold calibration method and apparatus calibrates a reference voltage representing a selected threshold and compares the reference voltage with a measurement voltage representing a variable parameter to indicate the condition of the variable parameter. The reference voltage is set by causing the variable parameter to assume a predetermined high value and adjusting a first potentiometer to provide a first calibration voltage equal to the measurement voltage representing the high value. The variable parameter is then caused to assume a predetermined low value and a second potentiometer is adjusted to provide a second calibration voltage equal to the measurement voltage representing the low value. The first and second calibration voltages are then combined using passive resistive components to provide a reference voltage representing the selected threshold.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a mount for a positionable object and has specific but not necessarily limited application to a ceiling or wall mount for a TV or a similar monitor.
2. Discussion of the Prior Art
Heretofore, wall and ceiling mounts such as those manufactured by Peerless Industries, Inc. and OmniMount Systems, Inc., while permitting the relatively heavy monitor to be adjusted around vertical as well as horizontal axes of limited rotation, nevertheless have been of rather difficult installation. Normally, at least two individuals are required to suspend the monitor in the mount. One individual is needed to support the mount while the second individual secures the suspended mount in position.
SUMMARY OF THE INVENTION
In this invention, the TV monitor is supported within a box-like frame with the top of the frame connected to a swivel part which is attached to either the ceiling or the wall. The monitor within its support frame is suspended from the swivel by a sliding lateral movement in which the ceiling or wall mounted part of the swivel enters a receptive slot at the top of the support frame. In this manner, only one individual is required to appropriately suspend the monitor with the mount.
Once suspended, an adjustment screw secured to the mount frame within a yoke attachment allows the frame and the supported monitor to be pivoted about a horizontal axis for adjustment of position. A safe limited range of movement of the frame and monitor about the horizontal pivot axis is provided by the yoke in conjunction with the adjustment screw.
It is an object of this invention to provide a mount for a TV monitor of economical construction and ease of operation.
Another object of this invention is to provide a mount which is for a monitor such as a television and which may be installed by one individual.
Still another object of this invention is to provide a monitor which is for a television or similar electronic apparatus and which may be mounted either to the ceiling or to the wall.
Other objects of this invention will become apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the mount of this invention showing the parts thereof with respect to one embodiment in separated form.
FIG. 2 is a view of the mount of FIG. 1 shown assembled but with swivel components separated.
FIG. 3 is an assembled view of the mount of FIG. 1 showing the swivel components connected.
FIG. 4 is a perspective view of the mount of FIG. 1 showing the swivel components in secured form.
FIG. 5 is an exploded view showing components of the swivel in exploded form.
FIG. 6 is a side view of another embodiment of the mount of this invention.
FIG. 7 is an end view of the mount shown in FIG. 6 but with the end plates removed.
FIG. 8 is a side view of the catch part of the embodiment of FIG. 1 .
FIG. 9 is a top view of the catch part shown in FIG. 8 .
FIG. 10 is an end view of the catch part shown in FIG. 9 .
FIG. 11 is a side view of the mount of FIG. 1 shown supporting a monitor.
FIG. 12 is a side view of the monitor shown in FIG. 11 but with the frame thereof tilted.
FIG. 13 is an end view in fragmentary form of the swivel and tilt components of the embodiment of FIG. 1 .
FIG. 14 is a fragmentary end view like FIG. 13 but showing the frame of the monitor in tilted position.
FIG. 15 is a perspective view of a ceiling support for the mount.
FIG. 16 is a perspective view of a wall support for the mount.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments hereinafter illustrated and described are not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described in order to best explain the principles of the invention so to enable others skilled in the art to best utilize the invention.
Mount 10 of this invention is shown in assembled form in FIG. 4 and in an exploded disassembled form in FIG. 1 . The mount includes a support frame 12 having sides 14 , bottom 16 , and top 18 . Sides 14 , bottom 16 , and top 18 are joined by suitable fasteners such as screws 20 and 20 ′ with a mounting plate 22 being connected to bottom 16 by fasteners 24 . A TV monitor 26 or a similar device is attached to mounting plate 22 . A particular component regarding frame 12 is catch part 28 which forms a part of the swivel 30 connecting frame 12 to the appropriate wall or ceiling attachment which will be later described. Catch part 28 forms a component of top 18 of the frame and includes upturned side walls 32 which parallel one another in a spaced-apart relationship. Extending between side walls 32 and forming a component of the catch part is retainer 34 . Retainer 34 includes an arcuate portion 36 which parallels the general transverse orientation of the frame. A slot 38 is formed in one of the catch part side walls 32 and extends into arcuate portion 36 of the retainer.
Swivel 30 includes in addition to catch part 28 , a barrel 40 suspended from a bolt or rotation member 42 retained within a cup part 44 . Bolt 42 extends through cup part 44 and is turned into a threaded bore 46 in barrel 40 and thereafter welded or otherwise fixedly secured to the barrel so that there is no rotative movement between the barrel and bolt 42 . A nut 48 previously turned upon bolt 42 is positioned between cup part 44 and barrel 40 . Nut 48 is tightened against the underside of cup part 44 once the frame and monitor is suitably oriented so as to secure the monitor and frame against pivotal movement about the vertical axis when in use. A key 50 is fixedly attached such as by welding to barrel 40 , extending the longitudinal length of the barrel. Key 50 includes an oval opening 52 .
Barrel 40 of swivel 30 may be suspended from a vertical stanchion 54 (see FIG. 15 ) carried by a mounting plate 56 which is adapted to be secured to a ceiling through suitable fasteners turned into the ceiling through openings 58 in the mounting plate. The lower end of stanchion 54 is threaded which permits the internally threaded cup part 44 to be turned and threaded on to the stanchion and there held in place against a rotative movement by a set screw 60 . Alternatively, a right angle bracket 62 (see FIG. 16 ) carrying a threaded stub 64 can be secured to a side wall 66 through lag bolts 68 or similar fasteners. Stub 64 is threaded in a fashion similar to stanchion 54 so as to allow cup part 44 to be turned upon the stub and secured in place by set screw 60 .
First, barrel 40 of swivel 30 is appropriately located and suspended through either stanchion 54 or bracket 62 depending upon the desired orientation and space availability of the room. With barrel 40 suspended and secured to either the ceiling or side wall mount, frame 12 and attached monitor can be picked up by one individual and moved over barrel 40 by having the barrel 40 fitted through slot 38 in catch part side wall 32 and retainer 34 with the barrel seating upwardly into the arcuate portion 36 of the retainer where it is nested. In this manner, a single individual can mount and support the frame with its monitor. A pair of end plates 70 are then inserted between the side walls 32 of catch part 28 and attached by a bolt 72 and nut 74 at each end of the barrel to anchor the barrel within catch part 28 . Nut 74 is preferably not tightened yet.
A bolt 76 is now fitted through an opening 78 in the forward positioned side wall 32 of catch part 28 . The bolt extends freely through opening 52 in key 50 secured to barrel 40 . A nut 80 is turned upon the extending end of bolt 76 and tightened against key 50 , as shown in FIG. 11 . Insertion of bolt 76 and the application of nut 80 is accomplished by the installer once the frame and monitor have been suspended from barrel 40 and are freely hanging in a vertical orientation such as shown in FIG. 11 and FIG. 13 . The installer then turns bolt 76 while holding nut 80 , both being accessible from either end of catch part 28 , causing the frame and its supported monitor to be drawn into a tilted position such as illustrated in FIG. 12 . In this manner, the angular position of frame 12 and the monitor can be set by the installer to accommodate the needs of the user of the monitor. The enlarged oval opening 52 in key 50 acts as a yoke and allows for a range of tilt of the frame while restricting the range within the confines of the area of opening 52 . In this manner, the frame with its limited range of tilt may be safely adjusted. At this time, nut 74 can be tightened upon bolt 72 to secure the end plates 70 in position within catch part 28 . The angular orientation of the frame, that is its position right or left relative to a vertical axis, is accommodated by the rotation of bolt 42 within cup part 44 . Once the frame and its monitor has been placed in its desired angular orientation, nut 48 is tightened against the bottom surface or base of cup part 44 , thus locking the frame and monitor against such a rotational movement relative to its attachment to the ceiling or wall.
FIGS. 6 and 7 depict a modified embodiment of the swivel connection. In this embodiment, cup part 44 is attached by bolt 42 and nut 48 to the catch part 28 ′. Catch part 28 ′ is a separate component and is in tubular form having a slotted opening 82 formed in one of its side walls. The frame 12 ′ (shown only partially for illustrative purposes) which supports the monitor includes a top 18 ′ having an upwardly extending stanchion 84 . Attached to the top of stanchion 84 is barrel 40 having its key 50 projecting upwardly. To hang or support frame 12 ′, the user lifts the frame carrying barrel 40 and the monitor with barrel 40 being inserted through slot 82 in catch part 28 ′ and lowered so that the barrel is seated upon the bottom wall 86 of catch part 28 ′. Slot 82 extends not only along the side wall of catch part 28 , but also in a narrow or restricted form along bottom wall 86 . This allows frame 12 ′ and barrel 40 to be seated within catch part 28 ′ and supported by having the opposite end portions of barrel 40 resting upon the unslotted portion of bottom wall 86 of the catch part.
Key 50 attached to barrel 40 in this embodiment has a slotted opening 88 . A side opening 90 is provided in catch part 28 ′ in the side wall opposite slot 82 . Bolt 76 is inserted through side opening 90 and opening 88 in the key with nut 80 being turned upon the bolt such as illustrated in FIG. 12 . Again, this is accomplished preferably after the frame and monitor has been suspended in catch part 28 ′ with the length of the catch part being such that easy access to the interior of the catch part is provided for the installer to insert bolt 76 and to apply nut 80 upon the bolt. While holding nut 80 , bolt 76 can be turned by the installer causing the frame 12 ′ to be tilted relative to catch part 28 ′. Also, the angular orientation of frame 12 ′ relative to cup 44 can be adjusted by movement of catch part 28 ′ and suspended frame 12 ′ about bolt 42 . Bolt 42 can be tightened to draw catch part 28 ′ against the base of cup part 44 with nut 48 being welded or otherwise secured against rotation within the interior of the cup part. End plates 70 can now be placed at the ends of barrel 40 and secured by bolt 72 and nut 74 .
The invention is not to be limited to the details above given but may be modified in the framework of the following appended claims. For example, in the embodiments shown in FIGS. 1–5 and 8 – 16 , the barrel may be attached to support frame 12 and catch part 28 attached to the vertical stanchion 54 . Analogous shapes may also be substituted to perform the intended function such as a ball may be substituted for barrel member 54 . Also, the shape of the key and slot could be varied to any configuration that will draw the frame when the bolt is turned. Furthermore, numerous frame shapes may be substituted for support frame 12 in lieu of the sliding channel members disclosed.
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A mount for an appliance such as a TV monitor which includes a box-like frame having a catch part at the top of the frame. A swivel part which may be attached to either the ceiling or the wall is provided. The catch part has a slot into which the swivel part is fitted, thus engaging the catch part to support the frame and the appliance. The disclosed support provides for ease of assembly as the appliance is supported from the ceiling or wall by the mere placement of said swivel in the catch part, without requiring any other assembly. The appliance may be tilted or rotated in the support.
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RELATED APPLICATIONS
[0001] This application claims the priority of German Patent Application No. 198 21 933.4 filed May 15, 1998, which is incorporated herein by reference.
BACKGROUND
[0002] The invention relates to devices for administering injectable products, in particular the injection of medically or cosmetically effective products.
[0003] Devices which the invention also concerns are known as injection pens. Generally, an injection pen comprises an elongated, hollow cylindrical housing in which a container, having the shape of an ampoule, filled with the product to be administered, is received. An injection needle is attached to the container and when so attached is generally axially aligned with or parallel to the central longitudinal axis of the housing, extending generally from one end of the housing. A drive unit for a piston within the container is also arranged in the housing. The piston is advanced in forward direction within the container under the effect of a driven member of the drive unit, thus causing a predetermined product dose to be dispensed. For advancing the piston, the driven member itself is advanced in the forward direction (i.e., toward the needle) in relation to the housing, either manually or by the drive force of a drive element of the drive unit. In the latter case, energy is stored in the drive unit, which energy is converted into a drive force driving the driven member forward upon the drive unit being actuated.
[0004] In the course of advancement of the driven member, the stored energy or at least part of the same is consumed. The drive force exerted by the drive element on the driven member is consequently reduced while the driven member is being advanced. Typically towards the end of the injection or dispensing cycle, the advancing or forward speed of the driven member decreases and, therefore, the dispensing rate will decrease, i.e., dispensing is not uniformly distributed over the total injection or dispensing cycle. Other interferences or counter forces may be caused by irregularities in the internal diameter of the ampoule, resulting in the wall frictional forces affecting the piston, causing non-constant piston movement over the stroke of the piston and making uniform dispensing or injection difficult.
SUMMARY
[0005] It is an object of the invention to provide for the uniform dispensing or injecting of an injectable product in devices for administering such products.
[0006] In one embodiment, the invention is an injection device comprising a base section and a drive unit including a driven member, a drive element and a damping arrangement. Typically, the base section may accommodate a container from which a product dose is dispensed through a needle by displacement of a piston in the container. The drive unit applies a force to advance the piston in the container to dispense a dose, and the damping arrangement is adapted to generally counteract the drive force and other counter forces produced during use of the device.
[0007] In another embodiment according to the invention, a device for administering an injectable product comprises a base section, a container arranged in or on the base section, from which container a product is dispensed through a needle by displacement, in a forward direction, of a piston being arranged in the container, and a drive unit comprising a driven member and a drive element, wherein the drive element exerts a drive force on the driven member upon the drive unit being actuated, thus displacing the driven member in the direction of forward advancement of the piston (toward the needle), thereby advancing the piston within the container. The drive force may be exerted on the driven member by a spring, but also by a pressurized fluid, such as compressed air. For actuation of the drive unit, a blocking means, preventing advancement of the driven member, is released. Preferably, in some embodiments, the drive force is not exerted on the driven member before the release of the blocking means. According to the invention, the device comprises means for generating a controlled damping force, counteracting said drive force in the course of the piston being advanced, in addition to unavoidable counter forces. The unavoidable counter forces essentially are frictional forces acting on the piston when the piston is advanced and any forces generated by the work of displacement the piston performs. Since in addition to these unavoidable counter forces a damping force is generated which counters the drive force, the force difference acting on the driven member and resulting from the drive force, the unavoidable counter forces and the damping force can be controlled much more accurately than is the case in prior art devices.
[0008] The damping force is advantageously set to ensure that the product is administered with the most constant dispensing rate possible. In most applications, the dispensing rate is constant upon the piston being advanced at constant speed. Accordingly, the damping force in one embodiment is generated relative to or dependent on the advancing speed of the piston, preferably directly dependent on the advancing speed of the driven member. An acceleration increases the damping force and a deceleration decreases the damping force. If the advancing speed is kept constant, the damping force remains constant. Self-regulation is particularly preferred.
[0009] In preferred embodiments, the damping force will be reduced at least once during forward movement. Preferably, the damping force cycle exerted over the advance stroke of the piston is adapted to the cycle of the drive force exerted by the drive element. When the energy of the drive element decreases, the damping force decreases.
[0010] In one variation, the damping force is generated by the fact that a volume change work must be performed for the advancement of the piston, due to a chamber increasing or decreasing in volume upon the piston being advanced, with pressure compensation in the chamber only taking place at a delayed rate. This system is self-regulatory since change in speed brings about a corresponding change in the damping force.
[0011] In another variation, the damping force itself is a frictional force. Due to the design of the components being in frictional engagement for this purpose, the damping force, in this case caused by friction, is controlled.
[0012] The invention is preferably used in injection devices. However, it is not limited to this application. In principle, it may be profitably used in all devices for administering products in which a drive force causes advancement of a driven member, including such devices wherein the drive force directly causes movement of the drive member, and/or in which the advancement of a piston results from the interaction of a drive force with unavoidable counter forces which are predetermined within or result from manufacturing tolerances.
[0013] Another object of the invention is to improve removal of a needle safety cap typically applied to the needle in injection devices, in which the needle is surrounded by a needle safety sleeve during transport of the device and only projects over or from a front end of the needle safety sleeve during an injection. In prior art devices of this type, in particular semi-automatic injection devices and fully-automatic injection devices, so-called auto-injectors, the needle safety sleeve is slotted in order to allow the user to remove the needle safety cap by access through the slot. However, this means that the needle is visible in the transport position of the device and, in particular, when inserting the needle, thus possibly producing in the user a psychological barrier against insertion of the needle.
[0014] The present invention in large part solves this problem by connecting a stripper to the device in such a way that the stripper is displaceable against the direction of advancement when inserting the needle. Once the stripper has fulfilled its function, i.e. stripped the needle safety cap from the needle, thus allowing simple, complete removal of the cap from the device, the stripper according to the invention does not impede injection, although it is still connected to the device, due to the stripper being either shifted into or over the needle safety sleeve when the needle is being inserted. The needle then also projects over or beyond a front end of the stripper. The stripper is provided with engaging means for clamping or gripping the needle safety cap, but which do not impede forward movement of the needle in relation to the stripper and the needle safety sleeve after the needle safety cap has been removed.
[0015] It is another object of the invention to provide a device according to the invention, which can be safely handled after administration of a product, as a uncovered projecting needle poses a safety problem after administration of a product dose. This object is addressed by the invention in that a needle safety sleeve connected to the device, displaceable in and against the direction of needle advancement, is blockable against retraction from a base position in which it surrounds the needle beyond its tip as a protection. Preferably blocking is effected by providing a blocking element or, in a solution that is preferred, by automatic retraction of the inserted needle after or injection.
[0016] An advantage of the present invention is the operational safety is enhanced. In a device according to the invention, particularly in an auto-injection device in which the needle is automatically advanced by advancement of the container in relation to the base section, the container is advanced against an elastic restoring force, returning the container for replacement into its rear position.
[0017] This advantage is based on the knowledge that when the needle safety cap covering the needle is retracted, the container is pulled slightly forward against said elastic restoring force, followed by rapidly and abruptly bouncing back into its rear position immediately after the cap has been pulled off due to the restoring force. The container can thereby be damaged. Operational safety is not only jeopardized by the risk of damage to the container, but also by any splinters possibly breaking off from the container which may block an advancement of the container required for inserting the needle. This risk is prevented according to the invention by releasably locking or blocking the container in its rear position, i.e., the base position prior to inserting the needle, against unintentional forward movement.
[0018] In one preferred variation of this embodiment, the same blocking element which is already used for blocking the displaceable needle safety sleeve, as described above, is also used for blocking the container against forward movement, i.e., the same blocking element may be optionally used for the two blocking functions described.
[0019] The stripper, the blocking of the needle safety sleeve and the blocking of the container may advantageously be used in connection with controlled damping, but may also be applied individually and in a suitable combination with each other.
[0020] Other objects, features and advantages of the device and method of the present invention will become more fully apparent and understood with reference to the following description and appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 depicts one embodiment of a device according to the invention,
[0022] [0022]FIG. 2 a depicts the stripper shown in FIG. 1 in a rear position,
[0023] [0023]FIG. 2 b depicts the stripper in a frontal position,
[0024] [0024]FIG. 3 depicts another embodiment of a device according to the invention,
[0025] [0025]FIG. 3 a depicts details of the embodiment shown in FIG. 3,
[0026] [0026]FIG. 4 a - e depicts an auto-injection embodiment including blocking of the needle safety sleeve,
[0027] [0027]FIG. 5 a - e depicts the auto-injection device in accordance with FIG. 4 a - e including blocking of the container,
[0028] [0028]FIG. 6 a - b depicts the auto-injection device in accordance with FIGS. 4 a - e and 5 a - e comprising an alternative release means, and
[0029] [0029]FIG. 7 a - c depicts an auto-injection device also including blocking of the needle safety sleeve.
DETAILED DESCRIPTION
[0030] The accompanying Figures and this description depict and describe embodiments of the injection device and method of the present invention, and features and components thereof. With regard to means for fastening, mounting, attaching or connecting the components of the present invention to form the device as a whole, unless specifically described otherwise, such means are intended to encompass conventional fasteners such as threaded connectors, snap rings, clamps such as screw clamps and the like, rivets, toggles, pins and the like. Components may also be connected by adhesives, glues, welding, ultrasonic welding, and friction fitting or deformation, if appropriate. Unless specifically otherwise disclosed or taught, materials for making components of the present invention may be selected from appropriate materials such as metal, metallic alloys, natural and manmade fibers, vinyls, plastics and the like, and appropriate manufacturing or production methods including casting, extruding, molding and machining may be used.
[0031] Any references to front and back, right and left, top and bottom and upper and lower are intended for convenience of description, not to limit the present invention or its components to any one positional or spacial orientation.
[0032] [0032]FIG. 1 is a longitudinal section of an injection pen, comprising an elongated, hollow cylindrical housing as a base section. The housing comprises a rear housing sleeve 4 being provided with an internal thread in a front section, and a front housing sleeve 7 being provided with an external thread in a rear section. The two housing sleeves 4 and 7 are screwed to each other in the sections of the two threads. A container 1 is arranged within the area of the front housing sleeve 7 and filled with an injectable product, in particular a fluid medicament.
[0033] The container 1 is an ampoule, common to such injection pens, including a piston 2 arranged in the same. By advancing the piston 2 towards an outlet at a front end of the container 1 , a product dose is displaced from the container 1 . An injection needle N is arranged on the container outlet pointing in the direction of advancement of the piston 2 . The needle N is covered by a needle safety cap 3 .
[0034] The container 1 is arranged in and centered by a container holder 30 . The container holder 30 , too, is formed by a sleeve and comprises in a front area three centering tongues 31 for centering the container 1 . Further tongues 32 are formed evenly distributed over the circumference of the container holder 30 between the centering tongues 31 and projecting over the front ends of the centering tongues 31 . The further tongues 32 act as stops when pushing back the needle safety sleeve 10 .
[0035] An intermediate sleeve 20 is arranged in an annular gap between the container holder 30 and the front housing sleeve 7 . The rear circumference of said intermediate sleeve 20 is provided with recesses through which the container holder 30 projects. Thereby, the container holder 30 is connected to the front housing sleeve 7 non-shiftably in relation to the front housing sleeve 7 ; in embodiment, the container holder 30 is screwed to the front housing sleeve 7 . In contrast, the intermediate sleeve 20 is displaceable in relation to the front housing sleeve 7 and the container holder 30 after release of a blocking means 21 , against the forward direction of the piston.
[0036] A releasing sleeve 35 is arranged in the rear housing sleeve 4 , a front face of which is in contact with a rear face of the intermediate sleeve 20 . The releasing sleeve 35 is essentially a hollow cylinder. A piston rod, extending rearwards from the piston 2 , projects through it. The releasing sleeve 35 is arranged in the rear housing sleeve 4 and longitudinally displaceable in either direction. It is driven by a restoring spring 9 into its frontal position, as shown in FIG. 1, in which it is positioned flush in contact with a rear face of the intermediate sleeve 20 and a rear flange face of the container 1 . A rear face 36 of the releasing sleeve 35 is chamfered outwards from a rear edge of an internal jacket face. When driving the releasing sleeve 35 back, said chamfered face 36 releases a drive unit for advancement of the piston 2 and dispensing the product.
[0037] The drive unit is formed by a driven member 40 and a drive spring acting as a drive element 49 , clamped between the driven member 40 and the rear housing sleeve 4 . The driven member 40 is pot-shaped, comprising a sleeve body open at its rear, formed by a simple circular cylindrical sleeve, projecting backwards from a closed sleeve bottom 41 . Said sleeve body is arranged in a surrounding internal sleeve 5 of the rear housing sleeve 4 , projecting forward from a rear face of the rear housing sleeve 4 . The internal sleeve 5 forms a slideway for the driven member 40 . In addition, it retains the driven member 40 against the force of the drive element 49 by a number of snap-on elements 6 being evenly distributed over a frontal circumference of the internal sleeve 5 (only one such element 6 is visible in the sectional view of FIG. 1) and surrounding a front face of the driven member 40 .
[0038] [0038]FIG. 1 shows the injection device in its base position prior to injection, in which the driven member 40 is blocked by means of the snap-on elements 6 and the needle N is surrounded by the needle safety sleeve 10 . Due to the needle N being surrounded by the needle safety sleeve 10 , the needle is covered for the user of the injection device, in particular when being inserted into the skin, thus reducing a psychological block against inserting the needle N into one's own skin.
[0039] For insertion, the needle safety sleeve 10 , together with the intermediate sleeve 20 and the releasing sleeve 35 , in relation to the housing sleeves 4 and 7 and the container holder 30 with the container 1 , can be shifted back against the forward direction (i.e., away from the needle). Furthermore, a sleeve-shaped stripper 60 is supported by the needle safety sleeve 10 . Said stripper 60 projects over a front face of the needle safety sleeve 10 and can be shifted against a restoring element 69 provided in the needle safety sleeve 10 , formed in the embodiment by a restoring spring, into the needle safety sleeve 10 . The stripper 60 serves to strip off a needle safety cap, already removed in FIG. 1. Its removal function will be described with reference to FIGS. 2 a and 2 b.
[0040] For injecting the product the injection device is positioned on and pressed against the surface of a tissue, generally the human skin. This pressure initially pushes the stripper 60 , forming the front end of the injection device, against the force of the restoring element 69 , into the needle safety sleeve 10 up to a stop position, in which it is completely or almost completely surrounded by the needle safety sleeve 10 . As soon as the stripper 60 has reached its stop position in the needle safety sleeve 10 , the user releases the blocking means 21 by pressing the releasing button 8 , thus releasing blocking against shifting of the intermediate sleeve 20 in relation to the front housing sleeve 7 .
[0041] Since the injection device is still pressed against the tissue, the needle safety sleeve 10 , and subject to the pressure exerted by the needle safety sleeve 10 , the intermediate sleeve 20 and therefore the releasing sleeve 35 , are pushed back within the housing. The needle N penetrates the tissue. Prior to the needle safety sleeve 10 with a rear stop face, formed by an all-round shoulder 12 projecting inwards from a rear section of the needle safety slave 10 , pushes against the tongues 32 of the container holder 30 , acting as a stop, the chamfered face 36 of the releasing sleeve 35 engages the snap-on elements 6 , and releases the fixation of the driven member 40 upon the sleeves 10 , 20 and 35 being driven back further. Release of the fixation occurs at the point in time when the needle N has reached its desired predetermined penetration depth.
[0042] At this point in time, the driven member 40 is driven by the drive force of the drive element 49 in forward direction against a rear face of the piston rod and drives the piston 2 forward within the container while being driven forward itself. Pushing the piston 2 forward dispenses the product from the container through its outlet and the needle connected to it. In some embodiments, the full content of the container is dispensed upon the drive unit being released. In such embodiments, the content of the container is the product dose. In principle, however, by a constructive further development of the injection device, several selectable product doses could be dispensed during a plurality of injections.
[0043] During advancement of the driven member 40 , the drive force stored in the drive element is gradually consumed when using a drive spring as a drive element 49 , for instance, in accordance with the characteristics of the spring. The advance speed of the piston 2 would therefore decrease during the course of advancement and the dispensing rate would decrease. In order to compensate for the reduction in drive force while the piston 2 is being advanced, a pneumatic damping force acting on the drive member 40 is generated.
[0044] For this purpose, the driven member 40 and the housing, i.e., the rear housing sleeve 4 form walls of a low-pressure chamber K, the volume of which increases during advancement of the driven member 40 . In this embodiment, the chamber K is formed by the sleeve bottom 41 and the sleeve body of the driven member 40 projecting from the same, and the rear face of the rear housing sleeve 4 and the internal sleeve 5 projecting from the same. The sleeve body of the drive member 40 and the internal sleeve 5 are displaced like telescopic sleeves in relation to each other. In the area of the slideways, i.e., between the external jacket face of the driven member 40 and the internal jacket face of the internal sleeve 5 , a surrounding seal 42 is arranged. In the embodiment, a washer is placed in a circumferential groove of the sleeve body of the driven member 40 .
[0045] The rear face of the rear housing sleeve 4 comprises a passage into which a seal 50 , having a calibrated through-bore, but otherwise being airtight, has been inserted. Instead of a calibrated through-bore, a one-way or non-return valve could be used, allowing the unimpeded escape of air upon the driven member 40 being driven back, but pressing against a valve seat on aspiration, thus leaving only a defined, narrow through-bore, as predetermined in the design. The volume flow admitted per time unit into the chamber K is in any case less per time unit than the increase in volume of the chamber occurring during the advancement of the driven member 40 , with a damping force therefore always being generated as long as the driven member 40 is advanced by the resulting drive force. The faster the driven member 40 is advanced the larger the generated damping force, i.e., the larger the effectively exerted drive force the larger the damping force generated. The type of damping force generation will therefore automatically compensate an energy consumption taking place in the drive unit, since with a decrease of the drive force a deceleration of the driven member 40 and a reduction of the damping force occurs. Simultaneously, other unavoidable or practically unavoidable counter forces are also compensated. Such superficial and other irregularities which cause deceleration or acceleration of the driven member 40 , are automatically accompanied by a change in the volume change work to be performed by the drive element 49 . An exemplary counter force is wall friction between the container 1 and the piston 2 , which is not identical everywhere over the stroke of the piston 2 within the container 1 . In addition, damping is further reduced due to the compressibility of the medium and the increase in chamber volume during the course of advancement of the driven member 40 , thus compensating twice for energy consumption.
[0046] [0046]FIGS. 2 a and 2 b show how a needle safety cap 3 may be removed by means of the stripper 60 . FIG. 2 a shows the needle safety cap 3 completely covering or surrounding the injection needle. This corresponds to the state of the injection device directly after inserting the container 1 and screwing the two housing sleeves 4 and 7 together. At the same time, this represents the transport position of the injection device until just prior to injection. For preparation for an injection, the needle safety cap 3 is initially removed.
[0047] [0047]FIG. 2 a shows how the removal of the needle safety cap 3 is initiated. For this, initially, the sleeve-shaped stripper 60 is pushed into the needle safety sleeve 10 against the pressure of the restoring element 69 until it presses against the needle safety cap 3 with two diametrically opposed engaging elements 61 . The two engaging elements 61 project obliquely inwards, like barbs, from the rear interior jacket face of the stripper. When pushing back the stripper 60 , the engaging elements 61 are more and more strongly pressed against the needle safety cap 3 which is widened towards the rear.
[0048] After firmly clamping the needle safety cap 3 between the engaging elements 61 , the stripper 60 may be released. It is returned by the restoring element 69 to its frontal position, as shown in FIG. 2 b , pushing it against a stop shoulder 11 of the needle safety sleeve 10 , thus stripping the needle safety cap 3 from the container 1 . In this position, the needle safety cap 3 , which now only loosely covers the needle N, may be easily and completely removed manually from the front. In order to simplify manual removal, the stripper 60 is provided with at least two gripping recesses 62 .
[0049] As the stripper 60 is permanently attached to the injection device, the user does not have to first tediously introduce it for removal of the needle safety cap 3 . On the other hand, it does not interfere in any way during injection. Another advantage resides in the fact that the needle safety sleeve 10 can be designed completely closed, i.e., without any gripping slot for removal of the needle safety cap 3 , thus allowing the needle N to be completely covered.
[0050] [0050]FIG. 3 shows an auto-injection device not only for automatically dispensing the product but also for automatically inserting the needle. Where the same references are used in FIG. 3 as in the embodiments described above, components of a substantially identical function are identified. As to the basic mode of operation of the auto-injection device, reference is made to the applicant's parallel German patent application No. 198 22 031 and the corresponding U.S. application Ser. No. , the disclosures of which are incorporated herein by reference:
[0051] In contrast to the embodiment of FIG. 1, damping of the drive force exerted on the driven member 40 in the auto-injection device of FIG. 3 is effected by mechanical friction. This damping frictional force is exerted between a contact pressure element 45 , designed as a pliable ring, clamped between the sleeve-shaped driven member 40 and a transfer member 46 which is also sleeve-shaped and surrounds the driven member 40 during advancement.
[0052] In the auto-injection device of FIG. 3, the injection cycle is essentially as follows: a blocking unit blocking the advancement of the driven member 40 is released by pressing a release tongue 8 , and the driven member 40 is driven forward to the left in FIG. 3, by the drive force of the drive element 49 , which is also a compression spring in this embodiment. Initially, the contact pressure element 45 forms a coupling between the driven member 40 and the transfer member 46 , as shown specifically in detail in FIG. 3 a . The driven member 40 drives the transfer member 46 via this coupling The transfer member 46 , in turn, advances the container 1 , including the needle N attached to the same at the front end, in relation to the housing.
[0053] Thereby, the needle N is pushed forward out of the needle safety sleeve 10 a and is inserted. The needle safety sleeve 10 a , in this embodiment, is firmly attached to the housing. Insertion is limited by stopping of the container holder 30 at the housing. When stopped, the coupling between the driven member 40 and the transfer member 46 is released, as clearly shown in FIG. 3 a . During further advancement, the driven member 40 is driven forward in relation to the transfer member 46 , presses against the piston rod and advances by it's own further advancement the piston 2 in the container 1 , thus allowing the product to be dispensed.
[0054] The contact pressure element 45 is a slotted spring washer similar to a piston ring. This washer is placed in an all-round groove on an external circumference of the driven member 40 , pressing elastically against the internal jacket slideway of the transfer member 46 . The wall frictional force exerted between the impression element 45 and the transfer member 46 decreases during the course of advancement of the driven member 40 , due to the internal jacket face of the transfer member 46 being widened in forward direction. This compensates for a decrease of the drive force of the drive element 49 .
[0055] A guide ring 47 is placed in a rear section of the transfer member 46 , serving as a straight guide for the driven member 40 . Said guide ring 47 may also be formed as a sealring comprising one or several calibrated through-bores or a non-return valve in accordance with the embodiment of FIG. 1. In this way a pneumatic damping force instead of or in addition to the frictional damping force could be generated. In such an embodiment, the low-pressure chamber would be formed in the gap section between the transfer member 46 and the driven member 40 being shifted into the transfer member 46 .
[0056] A tensioning handle, projecting through the housing, is used for returning into rear position and tensioning a holding and release sleeve 4 b together with the driven member 40 , the holding and release sleeve 4 b being displaceably arranged in the housing and jointly connected with the driven member 40 .
[0057] [0057]FIGS. 4 a - e and 5 a - e , which include elevational, sectional and cross-sectional views, show an auto-injection device in which the advancement of the container 1 for inserting the needle is effected in the conventional way by the piston 2 , in contrast to the device of FIG. 3, i.e. advancement of the container 1 is not decoupled from the advancement of the piston 2 , but is rather effected by the piston 2 . However, the injection device of FIGS. 4 a - e and 5 a - e , like that shown in FIG. 1, comprises a needle safety sleeve 10 , displaceable in either longitudinal direction in relation to the housing. This displaceable needle safety sleeve 10 covers the needle after injection, i.e. after retraction, which is not possible in the auto-injection device depicted in FIG. 3.
[0058] In contrast to the embodiment of FIG. 1, however, a stripper 65 is provided, not permanently connected to the injection device, but which must be inserted between the needle safety cap 3 and the needle safety sleeve 10 for removing the needle safety cap 3 until it grips behind the needle safety cap 3 like a claw, thus allowing removal of the needle safety cap 3 together with the stripper 65 .
[0059] [0059]FIG. 4 a - e shows an injection device after injection and retraction of the needle with the needle safety cap 3 already inserted on it for future transport. A special feature of this embodiment is the blocking of the needle safety sleeve 10 .
[0060] Blocking of the needle safety sleeve 10 securely ensures that the tip of the needle cannot freely project, thus eliminating any risk of damage to the needle N and in particular injury. The needle safety sleeve 10 is blocked by a blocking element 80 relative to the housing in such a way as to prevent the needle safety sleeve 10 being pushed back against forward direction.
[0061] The blocking element 80 is formed by means of a ring section comprising two engaging elements 81 , having the shape of two webs, projecting from an inner jacket face of said ring. As best shown in FIG. 5 a - e on the bottom left-hand side, the needle safety sleeve 10 comprises two slots 15 gripped by one each of the engaging elements 81 upon the blocking element 80 being placed on the housing. The engaging elements 81 then form stops for those walls of the slots 15 which extend in circumferential direction. The blocking element 80 is obtained by cutting a sleeve open, which sleeve is a circular annular sleeve in the embodiment, wherein cutting open occurs in longitudinal direction and outside of the central longitudinal axis of the sleeve, so that the blocking element 80 comprises a shell which when seen in cross-section, projects a little over the semicircle. Thus, the blocking element 80 as explained hereafter with reference to FIG. 4 a - e , is insertable over the rear housing sleeve 4 and projects over the largest diameter of the rear housing sleeve 4 when inserted over it.
[0062] As best shown in cross-sections B-B and C-C of FIG. 4 a - e , the blocking element 80 in carrying out its function as a block is retained on the needle safety sleeve 10 by means of its snap-in connection. For this the engaging elements 81 are designed flexibly and elastically and provided with snap-in projections at the front, gripping one of the internal slot edges after passing through each slot 15 , thus retaining the blocking element 80 like a snapper in blocked position, but allowing easy removal when required.
[0063] [0063]FIG. 5 a - e shows the blocking element 80 in its second function, in which it blocks the container 1 against advancement. Without this blocking, during removal of the needle safety cap 3 , the container 1 would be carried along in forward direction over a certain distance against the force of the elastic restoring element 29 and would snap back into its rear position depicted in FIG. 5 a - e the moment the needle safety cap 3 is removed, due to the force of the restoring element 49 . When snapping back, there would be a risk of damaging the container and an ensuing risk of possibly blocking forward movement of the container 1 when inserting the needle N.
[0064] In order to prevent this, the blocking element 80 is attached to a section of the housing covering the rear edge of the container 1 while the injection device is in its transport position until the needle safety cap 3 is removed. In this position, as shown in the longitudinal section of FIG. 5 a - e , the shell body of the blocking element 80 closely surrounds the housing, as shown in particular in cross-section E-E, and is retained to the rear housing sleeve 4 due to its ends projecting over the semicircle. The engaging elements 81 do not assume any retention function for the blocking element 80 , but now serve as a block for the container 1 . For this purpose, the engaging elements 81 grip through the housing and are positioned in front of an all-round flange provided at the rear end of the container 1 upon the blocking element 80 being attached. Since this rear flange of the container 1 , extending radially outwards, pushes against the engaging elements 81 of the blocking element 80 when removing the needle safety cap 3 , the container 1 is blocked in rear position and cannot therefore be advanced.
[0065] In its position shown in FIG. 5 a - e , the blocking element 80 fulfills a third function, namely to prevent release of the drive unit by blocking the movement of a release means 70 . The release means 70 is then able to release the driven member 40 from its blocked position when the blocking element 80 is removed from the housing, thus only allowing advancement of the release means 70 in relation to the housing at this point.
[0066] [0066]FIG. 6 a - b shows an auto-injection device which corresponds to the injection device of FIGS. 4 a - e and 5 a - e , except for the release means 70 for the driven member 40 . A release means 70 a of FIG. 6 a - b , too, consists of a sleeve-shaped body comprising a rear sleeve bottom. The driven member 40 is both blocked in its rear position by the release means 70 a and released when operating the release means 70 a accordingly.
[0067] The rear end of the driven member 40 ends in snap means, projecting through a rear face wall of the housing and surrounding its rear circumferential edge, with the snap means of the driven member 40 being pushed outwards due to their inherent elasticity and retained in their positions. As an additional security against unintentional disengagement, for instance due to impact, a blocking part 71 of the release means 70 a , which projects from its sleeve bottom and is formed as a small rectangle when seen in cross section, engages with its long side between two diametrically opposed snap means of the driven member 40 . In this rotational position, it prevents both snap means bending towards each other in the position of the release means 70 a shown in FIG. 6 a - b , which would release the snap-in connection. Furthermore, two contact pressure members 72 are projecting from the sleeve bottom of the release means 70 a at a distance from both sides of the blocking part 71 , which when seen in cross section have the shape of circular segments. The blocking part 71 projects over the contact pressure members 72 . The blocking element 80 is initially removed for release of the driven member 40 , followed by rotating the release means 70 a at least so far around its longitudinal axis that the snap means of the driven member 40 can be bent towards each other. During rotation of the release means 70 a , the contact pressure members 72 are positioned over the snap means of the driven member 40 when seen in cross section. When pushing the release means 70 a towards the driven member 40 , the impression elements 72 push against the snap means of the driven member 40 , which comprise chamfered rear faces, thus allowing them to bend towards each other under the pressure of the impression members 72 , thereby releasing the snap-in connection of the driven member 40 with the housing. Due to the pressure exerted by the drive unit 49 the driven member 40 is then driven forward.
[0068] The blocking element 80 may be designed as a rotary element instead of a plug-in element and could, therefore, remain on the housing after blocking of the container has been released.
[0069] [0069]FIGS. 7 a , 7 b and 7 c show the mode of operation of the needle protection apparatus which prevents the needle N from freely projecting from the housing after retraction from the tissue when it could be broken and/or cause injury if not handled carefully. A feature of the needle protection apparatus is that the needle safety sleeve 10 , which is displaceable in relation to the housing for the purpose of insertion, is blocked in a needle protection position after retraction of the needle, so that it can no longer be pushed into the housing. Pushing over the housing externally would also be feasible. The mode of operation of the pen for inserting the needle N and dispensing the product corresponds to that of the pen shown in FIG. 3.
[0070] [0070]FIG. 7 a shows the front section of the pen in its base position directly before injection. FIG. 7 b shows the pen in the frontal position of the container 1 , i.e. in injecting position. The needle safety sleeve 10 has been pushed against the force of the restoring element 19 into its most rear displacement position in relation to the housing sleeve 7 . The needle N projects out of the housing and the needle safety sleeve 10 by the desired length.
[0071] The needle safety sleeve 10 comprises a rear stop face and a front stop face, limiting the displacement path of the needle safety sleeve 10 in relation to the front housing sleeve 7 in and against forward direction. When moving the needle safety sleeve 10 in either direction, it passes over a blocking sleeve 80 ′ provided in the housing and secured against displacement and preferably also rotation, said blocking sleeve 80 ′ comprising at its front end at least one hook 82 which is chamfered outward obliquely or curved. In an internal jacket section, with which it slides over the hook 82 , the needle safety sleeve 10 comprises a widened section, extending approximately over the length of its maximum displacement path, the widened section being preferably a slightly widened internal diameter. A transitional section 14 extending between the widened section and the adjacent internal cross section is chamfered, thus enabling the needle safety sleeve 10 to slide over the hook 82 , subject to the pressure of the restoring element 19 , up to a point behind the transitional area 14 . Behind the transitional area 14 , in a central section the needle safety sleeve 10 is provided with longitudinal slots 15 , the front faces 16 of which, as best shown in FIG. 7 c , form stop faces each for one of the hooks 82 .
[0072] The blocking sleeve 80 ′ ends in a number of elastic and flexible tongues 83 , evenly distributed over the circumference of the sleeve, the free front ends of which are each formed as a hook 82 . The container holder 30 also ends in tongues 33 towards its free front end. When advancing the container holder 30 against the force of the restoring element 29 , these tongues 33 are positioned below the tongues 83 of the blocking sleeve 80 ′. Each of the tongues 83 is thus supported radially towards the inside and can no longer be bent radially inward when the container is in its frontal position. The tongues 83 are not only supported by the tongues 33 but are in addition pushed radially outwardly. In comparison with the tongues 83 , the tongues 33 are rigidly formed and may be more rigid than tongues 83 .
[0073] After retraction of the needle N, the needle safety sleeve 10 is pushed forward again by the restoring element 19 . Due to the chamfered face 14 and/or the chamfered shape of the at least one hook 82 , the needle safety sleeve 10 is pushed over said hook 82 , the end tip of which is, furthermore, elastic and flexible. However, as soon as the needle safety sleeve 10 has been advanced again to a point at which its stop face 16 is positioned in front of the hook 82 , when seen in forward direction, it is blocked against return by the hook 82 positioned against the stop face 16 in stop position. The hook 82 and the needle safety sleeve 10 are in contact with each other by their stop faces which point vertically to the direction of displacement. In its safety position shown in FIG. 7 c , the needle N is protected after injection by means of the needle safety sleeve 10 .
[0074] The container holder 30 is therefore simultaneously used as a displaceable support for the at least one elastic blocking means 82 and fulfills, according to the invention, the dual function of retaining the container 1 and blocking the needle safety sleeve 10 . The needle safety apparatus does not require the auto-injection device to be designed according to the invention, although it is used most preferably in combination with the same. It may also be used to advantage in generic auto-injection devices.
[0075] The foregoing description of embodiments of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. The above described embodiments were chosen and described to provide an illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when the claims are interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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The invention provides a injection device for administering an injectable product, including a base section adapted to receive a container from which a product dose is dispensed through a needle by displacement of a piston in the container, and a drive unit including a driven member, a drive element and a damping arrangement, the drive unit for applying a force to advance the piston in the container to dispense a dose, wherein the damping arrangement generally counteracts the drive force and counter forces. The invention also encompasses a needle safety sleeve and a blocking structure for use with injection devices.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for finishing pieces cut from a length of textile material unwound from a roll by sewing their leading edge, particularly for closing the leading edge of a tubular piece.
Hereinafter, for the sake of convenience of presentation, the term “length” is understood to designate woven or non-woven textile articles of different kinds, composed of one or more layers, even tubular and mutually different as for quality and consistency, while the term “piece” is understood to designate a portion cut from said length of textile material.
In the preparation of pieces of textile material, particularly padded pieces as used for example to cover mattresses or to prepare quilts, the need is felt to finish the leading edge in order to keep the various layers of the piece properly superimposed one another and avoid staggering of the edges, so that the piece can be positioned easily for the subsequent processes.
This need is felt even more when the pieces are cut from a length of textile material composed of multiple layers and unwound from a roll, or when the length of textile material is prepared by joining multiple layers unwound from respective rolls.
Tubular pieces are also known which are used to cover, for protective purposes, blocks of rubber latex, for example in the manufacture of mattresses.
Such tubular pieces, once cut to size from the unwound length of textile material, must be closed at one end so as to form a pouch for containing the latex block.
SUMMARY OF THE INVENTION
The aim of the present invention is therefore to provide an apparatus that is suitable to be inserted in a line for producing pieces of textile material, particularly tubular pieces, and allows to meet this requirement.
Within this aim, an object of the present invention is to provide an apparatus that is relatively simple to manufacture and therefore economically advantageous.
This aim and this and other objects which will become better apparent hereinafter, are achieved with an apparatus for finishing a piece cut from a length of textile material unwound from a roll by sewing its leading edge, particularly for closing the leading edge of a tubular piece, characterized in that it comprises: means for causing the advancement of said length of textile material, suitable to unwind two successive portions of the length of material, for a total longitudinal extension equal to the longitudinal extension of said piece; cutting means, arranged downstream of said advancement means and suitable to cut a piece from said length of textile material with a cut that is perpendicular to said unwinding direction and forms the rear edge of the cut piece and the leading edge of the length of textile material to be unwound; positioning means, arranged downstream of said cutting means and suitable to arrange the leading edge of said unwound length of material with respect to a sewing machine; said advancement, cutting and positioning means being coordinately operatable so that: in a first step, said advancement means unwinds said length of material for a said first portion whose longitudinal dimension is such that said leading edge is engaged in said positioning means; in a second step, said positioning means is actuated so as to position said leading edge in alignment with the sewing path of said sewing machine; in a third step, said sewing machine is actuated so as to produce a stitched seam along said leading edge; in a fourth step, said advancement means unwinds a said second portion from said length of material; and in a fifth step, said cutting means cuts a piece from said length of material.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become better apparent from the following description of a preferred embodiment thereof, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a partially schematic perspective view of the apparatus;
FIG. 2 is an axial schematic view of the apparatus of FIG. 1 in the initial condition of the operating cycle;
FIG. 3 is an enlarged-scale view of a detail of FIG. 2;
FIGS. 4, 5 , 6 and 7 are schematic views of the apparatus of FIG. 1 in four successive operating situations;
FIG. 8 is a view of a second embodiment of the apparatus;
FIGS. 9, 10 , 11 , 12 , and 13 are schematic views of a third embodiment in five operating situations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Specifically with reference to FIG. 1, the apparatus comprises means (not shown) for rotatably supporting a roll 1 on which a length of textile material 2 , from which the pieces to be finished will be obtained, is wound. The length of material 2 is constituted for example by a tubular article for wrapping latex mattresses, or by a plurality of superimposed layers. In this last case, the length of material, instead of being pre-manufactured and wound on a single roll, can be produced by conveying and coupling at the inlet of the apparatus individual layers unwound from a corresponding number of rolls.
The length of material 2 is unwound from the roll 1 in the direction A by means of an advancement assembly generally designated by the reference numeral 3 . Said assembly 3 is composed of two parallel grip rollers 4 and 5 , between which the length of material is guided from above. The rollers 4 and 5 are perpendicular to the direction A and have, at one end, respective gears 6 and 7 that mesh with each other and are actuated so as to rotate in opposite directions by means of an electric motor 8 and a transmission composed of a belt 9 wound on a pair of pulleys that are keyed respectively to the output shaft of the electric motor 8 and on the roller 4 adjacent to the gear 6 .
Below the grip and unwinding assembly 3 and at the rear of the length of textile material 2 , a rail 10 is provided, which is parallel to the rollers 4 and 5 and acts as a sliding guide for a carriage 11 that comprises a bracket on which an electric motor 12 is supported, said motor having a shaft with a vertical axis that protrudes upward. A disk-like blade 13 is keyed to the shaft 12 and intersects the plane of the length of material 2 below the rollers 4 and 5 .
The carriage 11 is rigidly coupled to a portion of a transmission belt 14 that is parallel to the rail 10 . The belt 14 is wound in a closed loop around a driven pulley 14 a and around a driving pulley 15 actuated by an electric motor 16 .
At the rear of the length of material 2 , i.e., on the side engaged by the roller 4 , and below the grip and unwinding unit 3 , there is an abutment bar that is parallel to the roller 4 and is composed of two L-shaped profiled elements 17 a and 17 b , between which there remains a gap 17 c along which the blade 13 can slide. Opposite the abutment bar 17 a and 17 b , but on the opposite side of the length of material 2 , there is a locking bar 18 , constituted by a profiled element that has a C-shaped cross-section with two superimposed longitudinal wings 18 a and 18 b that delimit a longitudinal gap 18 c that is directed toward the length of material 2 and faces the gap 17 c . The profiled element 18 is supported, at the level of the circular blade 13 , by two pneumatic actuators 19 and 20 , which are suitable to move it between a position that is spaced from the length of material 2 and a position for locking the length of material 2 between the profiled elements 17 a and 17 b and the wings 18 a and 18 b in order to allow the blade 13 to slide in the gaps 17 c and 18 c during the cutting of the end portion of the piece 2 that will constitute the piece to be finished.
Below the bar 10 and parallel thereto there is an abutment bar 21 to which a plurality of equidistant elastic tabs 22 are fixed. The tabs 22 are substantially perpendicular to the plane of the length of material 2 and protrude so as to form a sort of comb.
Proximate to the bar 21 , but at the rear of the length of textile material 2 , a strip 23 is articulated which is actuated by pneumatic actuators 24 capable of imparting to the strip an oscillation of 90° between a vertical position and a horizontal position. In the vertical position, the strip 23 is flush with the length of material 2 , while in the horizontal position the strip 23 arranges itself below the tabs 22 and so that its free edge coincides with the ends of the tabs.
In front of the abutment bar 21 and parallel thereto there is a rail 24 a that acts as a guide for a slider 25 . The slider 25 supports a sewing machine 26 whose working plane is co-planar to the plane formed by the tabs 22 .
The slider 25 is actuated with a reciprocating motion along the rail 24 a so that the sewing machine 26 can be moved from one end to the other of the abutment bar 21 . For the actuation of the slider 25 along the rail there is an electric motor 27 provided with a vertical output shaft on which a driving pulley 28 is keyed. A belt 29 is wound around the driving pulley 28 and is closed in a loop around a driven pulley 30 . The portion of the belt 29 is parallel to the rail 24 a and the slider 25 is fixed thereto in a manner similar to the fixing of the carriage 11 to the belt 14 .
The operation of the apparatus is described hereinafter assuming that the apparatus is in the position assumed at the end of an operating cycle shown in FIG. 2 . In this position, the locking bar 18 is kept spaced from the length of textile material 2 , which by being fed by the grip unit formed by rollers 4 and 5 can slide between the profiled elements 17 a and 17 b and the bar 18 . The strip 23 is turned vertically downward and the sewing machine 26 is in stand by at one end of the rail 24 .
While the initial end of the length of textile material 2 is gripped between the rollers 4 and 5 , the motor 8 is activated (see FIG. 4) and, by actuating the rollers 4 and 5 so that they rotate in opposite directions, causes the unwinding of the length of material 2 by a preset extent. The portion of the length of material 2 which, due to the traction produced by the rollers 4 and 5 , is unwound from the roll 1 , after passing between the profiled elements 17 a and 17 b and the abutment bar 18 , arranges itself between the strip 23 and the bar 21 . The portion of the length of material 2 that is unwound in each instance from the roll 1 has such a longitudinal dimension that its leading edge 31 protrudes slightly below the edge of the strip 23 .
At this point, the cylinders 24 are activated, turning the strip 23 horizontally below the tabs 22 (see FIG. 5) so as to block the front transverse margin 32 of the length of material 2 so that its leading edge 31 , by protruding forward from the tabs 22 and from the strip 23 , is now positioned on the line of advancement of the needle of the sewing machine 26 .
By activating the motor 27 , the sewing machine 26 is made to advance along the rail 24 a so as to sew the leading edge 31 . Once sewing has been completed, the cylinders 24 are actuated, returning the strip 23 to the vertical position (see FIG. 6 ).
In the subsequent step (see FIG. 7 ), the rollers 4 and 5 of the assembly 3 are activated again, unwinding from the roll 1 a portion of the length of material whose longitudinal dimension corresponds to the longitudinal dimension of the piece 33 to be obtained.
Then the pneumatic cylinders 19 and 20 are activated, causing the advancement of the bar 18 until the edges of the wings 18 a and 18 b that delimit the gap 18 c abut against the profiled elements 17 a and 17 b , thus locking the length of textile material 2 . Once the length of material 2 has been clamped, the electric motor 16 is activated and causes the advancement of the carriage 11 and therefore of the cutting assembly mounted thereon. In this manner, the rotating blade 13 , by advancing along the gaps 17 c and 18 c transversely to the unwinding direction A, cuts from the length of textile material 2 a piece 33 whose longitudinal dimension is equal to the longitudinal dimension between the edge 31 and the gap 18 .
The operating cycle is then repeated in the manner described above.
It is evident that the described apparatus allows to work on individual pieces obtained from a continuous length of textile material wound on a roll. This ensures that the various layers that compose the piece, once the cutting of the length of material has been completed, cannot arrange themselves out of place during the handling to which they are subjected in order to be prepared for successive treatments such as bordering, quilting and so forth. If the tubular part is constituted by a tubular article, the stitched seam closes the leading edge and forms a pouch that can be used to cover mattresses or the like.
In the practical embodiment of the invention, numerous modifications and variations are possible all within the scope of the same inventive concept.
In a second embodiment of the invention, the tabs 22 for elastic retention of the margin 23 of the length of textile material are obtained by cutting notches 34 into a metal plate as shown in FIG. 8 .
In a third embodiment of the invention (see FIGS. 9 - 13 ), the bar 21 is articulated about an axis 35 located at a higher level than the axis 36 of the strip 23 . A metal plate 37 is rigidly coupled to the bar 21 , instead of the tabs 22 , and in the inactive position arranges itself by gravity parallel to the strip 23 at a distance that is greater than the thickness of the length of textile material 2 . The height of the metal plate 37 is such that its free edge 38 is arranged at an intermediate level of the strip 23 .
By way of the distance between the walls of the metal plate 37 and of the strip 23 , when said strip is turned so as to tilt horizontally the margin 32 , said margin is locked by the edge 38 against the strip 23 . As the rotation of the strip 23 continues, the axial offset of the axes 35 and 36 causes a sliding of the edge 38 on the strip 23 and the gradual expulsion of the margins 32 beyond the edge of the strip 23 .
Once the strip 23 has reached the horizontal position, the edge 31 of the margin 32 is aligned with the sewing path of the sewing machine 26 .
The disclosures in Italian Patent Application No. BO2000A000716 from which this application claims priority are incorporated herein by reference.
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An apparatus for sewing finishing a piece cut from a length of textile material unwound from a roll and closing the leading edge thereof, comprising: advancement rollers for advancement of the length of textile material, to unwind two successive portions of the length of material, for a total longitudinal extension equal to the longitudinal extension of the piece; a cutting blade suitable to cut a piece from the length of textile material with a cut that is perpendicular to the unwinding direction and forms the rear edge of the cut piece and the leading edge of the length of textile material to be unwound; and positioning elements for arranging the leading edge of the unwound length of material with respect to a sewing machine.
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BACKGROUND OF THE INVENTION
The invention relates to a method of forming a configuration of interconnections on a semiconductor device, more particularly an integrated circuit, this method comprising the following steps:
(a) forming an insulating layer on the substrate, in which the elements of the device are provided,
(b) etching narrow contact openings into this insulating layer,
(c) depositing at least one layer of conductive material by means of a method ensuring a good coverage, inclusive of the inner surface of the contact openings, the overall thickness of said layer being sufficient to fill the volume of the contact openings,
(d) removing by etching the major part of the conductive material to expose the surface of the insulating layer, but to maintain the material in the contact openings,
(e) depositing a metallic interconnection layer and etching it into the form of the desired configuration.
The semiconductor technology shows a constant development towards an increasingly higher integration of the number of elementary parts in the same monolithic circuit.
For this purpose and in order to increase the speed of operation of the circuits, there is a tendency to reduce as far as possible the dimensions of the elementary parts. The conventional techniques of forming contacts on the semiconductor devices used until recently contact zones and interconnection lines whose lateral dimensions most frequently were considerably larger than the thickness of the metallic layer constituting the said lines. As far as the manufacture of circuits having a high integration density is concerned, it is on the contrary necessary to provide contact openings whose diameter is of the same order as the thickness of the insulating layer, in which these contact openings are formed. In this connection, reference is frequently made to the ratio between the depth and the diameter of the contact openings designated as "aspect ratio", which, when this ratio is close to 1 or even larger, indicates that the known techniques of forming contacts based especially on the simple deposition of an aluminum layer can no longer be used successfully.
Thus, the method mentioned in the opening paragraph has been proposed to provide a solution suitable for the formation of a configuration of interconnections on a circuit having a high integration density, in which the contact openings have an aspect ratio close to or larger than 1.
A method of this kind is known from the document EP-A-0 165 185. Among the conductive materials intended for filling the contact openings, titanium and tungsten are mentioned. It is otherwise known that a particularly interesting solution from the viewpoint of performances: especially a low electrical resistance and a good mechanical behaviour, consists in that first a thin layer of titanium-tungsten alloy is used as adhesion and covering layer for the whole surface and then a thick layer of tungsten is formed for effectively filling the contact openings.
The method generally used for depositing the tungsten layer for filling the contact openings is that designated as low-pressure chemical vapour deposition (LPCVD) method.
In fact this method ensures a good coverage of the whole surface from the layer of Ti-W alloy serving to activate the nucleation of deposition of tungsten. The filling of the contact openings is obtained when the thickness of the deposited layer is at least equal to half the diameter of these openings.
According to this method, after etching the layer of tungsten in such a manner that only the parts of this layer contained within the contact openings are maintained, it is observed that the upper surface of the insulating layer thus exposed frequently has a more or less pronounced roughness which can be irregularly disturbed over the substrate.
This degradation of the flatness of the surface of the insulating layer seems to be associated with the formation of micro-crystals in the layer of conductive material serving for filling the contact openings. In fact, this layer is necessarily fairly thick and is therefore obtained in conditions which promote a comparative high rate of deposition in such a mannner that the method remains economical.
During the step of etching the conductive material, it is common practice that the etch employed is not selective with respect to the material of the insulating layer and that there is therefore a tendency to attack a superficial fraction of said insulating layer in order to guarantee the complete elimination of the conductive material everywhere except in the contact openings.
The surface roughness is then associated with the insulating layer.
The continuation of the manufacturing process of the semiconductor device is seriously disturbed by the appearance of this fault. In fact, the surface roughness of the insulating layer influences the crystallization of the metallic interconnection layer generally made of aluminum, which subsequently covers it and result in a reduction of the resistance to electromigration of this metallic layer.
On the other hand, the roughness is also reproduced at the surface of the metallic layer and during the operation of photomaking this layer leads to a substantial degradation of the optical definition of the masque of lacquer to be formed for locally etching the metallic layer.
SUMMARY OF THE INVENTION
Thus, the invention has for its object to provide an improvement of the indicated method such that the aforementioned difficulties are avoided.
According to the invention, a method of forming a configuration of interconnections on a semiconductor device, more particularly an integrated circuit, comprises the following steps:
(a) forming an insulating layer on substrate, on which the elements of the device are provided,
(b) etching narrow contact openings into this insulating layer,
(c) depositing at least one layer of conductive material by means of a method ensuring a good coverage inclusive of the inner surface of the contact openings, the overall thickness of this layer being sufficient to fill the volume of the contact openings,
(d) removing by etching the major part of the conductive material to expose the surface of the insulating layer, but to maintain material in the contact openings,
(e) depositing a metallic interconnection layer and etching it into the form of the desired configuration,
and is characterized in that, before the contact openings are etched (before the aforementioned step b), the insulating layer is covered by a so-called separation layer of such a kind that it can be etched selectively with respect to the insulating layer and in that openings corresponding to the contact openings are etched into the separation layer, whereupon the steps of method indicated at b, c and d are effected, and in that, before the metallic interconnection layer is deposited (step e), the separation layer is selective eliminated.
Since the separation layer is eliminated selectively with respect to the insulating layer, not a single surface irregularity that may be carried by the separation layer can be transmitted by etching to the surface of the insulating layer, which retains its original flat state.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1, 2, 3a, 4a and 5a show diagrammatically and in sectional a part of the semiconductor during various successive stages of the method according to a first embodiment of the invention;
FIGS. 3b, 4b and 5b show views similar to those of FIGS. 3a, 4a and 5a, but of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to an advantageous embodiment of the invention, the separation layer is chosen so that it can be eliminated selectively with respect to the conductive filling material. Thus, by the value of the thickness given to the separation layer there is a parameter which permits of adjusting after removal of the major part of the conductive material the upper level of the remaining parts of this material in the contact openings with respect to the level of the surface of the insulating layer. It has in fact been found that the quality and the regularity of the contacts obtained by the aforementioned method depended for a substantial part upon the fact that the level of the parts of the conductive material is not lower than the level of the adjacent insulating layer and that these parts of conductive material on the contrary form a protuberance having a controlled value, which facilitates a low-resistance contact with the metallic layer subsequently covering it.
According to a first detailed embodiment of the invention, the method is characterized in that the insulating layer is formed by a silica glass, the filling material is formed by tungsten or an alloy rich in tungsten and the separation layer is formed by silicon nitride.
In this case, with respect to the choice of the thickness of the separation layer, the superficial fraction of this layer which will be eliminated during the continued step of etching the tungsten layer when this attack is slightly prolonged in order to take into account small operating tolerances, which are in practice inevitable, should be taken into account.
The etching selectivity of silicon nitride with respect to silica glass permits eliminating the separation layer, which leaves the surface of the insulating layer in its original state, i.e. devoid of roughness.
According to a second embodiment of the invention, the method is characterized in that the separation layer is chosen to be of such a kind that the conductive filling material can be etched selectively with respect to the separation layer, which is used during the step of etching the conductive material (step d of the method) as an etch-stopping layer.
According to this embodiment, the separation layer is practically not consumed at the end of the elimination of the conductive material and the elimination of the roughness of the surface is obtained from this stage of the method.
According to an advantageous variation of this second embodiment, during the step of etching the contact openings, the separation layer is etched selectively, this layer serving as an additional mask for etching the insulating layer. Since precisely contact openings should be formed having a high aspect ratio for which practically vertical walls of the openings should be obtained, advantageous anisotropic attacking conditions can be chosen, in which the separation layer plays the part of a mask having a higher resistance than the mask of photoresist used in initially for defining the openings in the separation layer.
According to a preferred variation of the second embodiment of the invention, the method is characterized in that, the filling conductive material is formed by tungsten or an alloy rich in tungsten and the separation layer is formed from one of the metals aluminum, an alloy of aluminum or cobalt.
In order that the invention may be readily carried out, it will now be described more fully, by way of example, with reference to the figures accompanying drawing.
The method according to the invention relates to the manufacture of a configuration of interconnections on a semiconductor device, of which a part shown diagrammatically in FIG. 1.
The different active elements of an integrated circuit have been formed in a substrate 10 of, for example, silicon, the different stages of the method to be described serving to form an electrical contact with an active region 11 of the device, which may be, for example, a source or drain region of a field effect transistor of the MOS type. An insulating layer 12 most frequently made of silica glass that may be doped with phosphorous or boron is formed on the substrate 10.
In order to ensure a suitable insulation of the configuration of interconnections which will subsequently be carried by the insulating layer 12 and in order to reduce to a minimum the parasitic capacitance of this configuration with respect to the substrate, the insulating layer 12 has a comparatively large thickness, of the order of 0.8 to 1 μm.
According to the method of the invention, the insulating layer 12 is covered with a so-called separation layer 13 of such a kind that it can be etched selectively with respect to the insulating layer 12. In accordance with the material chosen to form the separation layer 13, the thickness of this layer can be varied, but nevertheless it generally lies between 50 nm and 300 nm. The assembly of the device has then been covered with a photoresist mask 15, in which openings 16a are formed at the areas at which contacts have to be provided.
As is shown in FIG. 2, by means of the mask 15 an opening 16b is etched into the separation layer 13 and then an opening 16c is etched into the insulating layer 12, the opening 16c having a depth such that the surface of the active region 11 is esposed. In order to limit as far as possible the volume of the elements of the integrated device, the diameter of the contact openings, such as 16c, is, for example, 0.8 μm so that these openings have an aspect ratio equal to or slightly larger than 1. In order to obtain contact openings 16c, whose walls are practically vertical, an anisotropic etching method is used which is known as "reactive ion etching". For etching the opening 16b into the separation layer 13, use is made of an etching technique directly associated with the kind of the material chosen to form this layer, further details about this technique being given below.
However, it should be noted that the separation layer 13 has a thickness such that the opening 16b formed therein has an aspect ratio considerably smaller than 1 and that consequently the angle of the walls of this opening 16b is not so important as for the opening 16c in the insulating layer 12.
Reference is now made to FIG. 3A, which corresponds to the stage of the method at which a layer of conductive material 18 is deposited having a sufficient thickness so that the contact openings 16b, 16c are entirely filled with this conductive material. For this purpose, a method is used known to ensure a good coverage of the surface, inclusive of the inner surfaces of the contact openings. Among these known methods is the so-called low-pressure chemical vapour deposition (LPCVD) method or atmospheric pressure chemical vapour deposition method (CVD). As conductive material 18 tungsten, an alloy of tungsten an titanium, an alloy of tungsten and silicon or highly doped polycrystalline silicon to be sufficiently conducting can be chosen.
The following operation consisting in removing by etching the major part of the conductive material 18 is shown in FIG. 4A. The conductive material 18 is preferably etched in a plasma, whose kind depends upon the kind of the conductive material used. In the case of tungsten or of an alloy of tungsten or of an alloy rich in tungsten, for example, a plasma of sulphur hexafluoride (SF 6 ) can be used. Since it is attempted to expose entirely the surface of the separation layer 13 so that only elements 18a of the local conductive material within the contact openings 16c are maintained, it is necessary to slightly prolong the attack in order to take into account possible tolerances of the thickness of the conductive material 18 or slight variations in the operating conditions. In accordance with the kind of the separation layer 13 and its more or less high resistance to this attack, the level of the element 18a of conductive material can therefore be situated slightly below the level of the separation layer 13 at the end of the etching step. The termination of the attack is defined either by an accurate control of the etching time or by an arbitrary detection means especially utilizing the variation in intensity of a specific jet emitted by the plasma.
The following operation consisting in eliminating the separation layer 13 is carried out selectively with respect to the insulating layer 12. Consequently, the surface of the insulating layer 12 thus exposed is devoid of any irregularity independently of the possible roughness of the surface of the separation layer 13. Advantageously, the material of the separation layer 13 will be chosen so that it can be eliminated selectively with respect to the conductive material 18. Thus, as shown in FIG. 5A, the upper level 20 of the element 18a of conductive material may be made higher, if desired, with respect to the level 21 of the surface of the insulating layer 12. Such a shift is obtained by differences with respect to the thickness of the separation layer 13, which is eliminated.
According to a first practical embodiment of the invention, the separation layer 13 is made of silicon nitride (Si 3 N 4 ). At the end of the attack of the layer of conductive material 18, the separation layer 13 does not exhibit an etching barrier, but is on the contrary attacked at a rate which is of the same order as the rate of attack of the conductive material 18 in the case in which this material is tungsten or an alloy rich in tungsten. A thickness of the separation layer 13 has to be chosen which corresponds to the time for which the etching of the layer of conductive material 18 is prolonged because a superficial part of the separation layer 13 will be etched during this prolongation of the etching treatment. By way of example, a thickness of 150 to 300 nm for the separation layer 13 of Si 3 N 4 has proved to be suitable. Since silicon nitride can be etched selectively both with respect to silica glass and with respect to tungsten while wet wet etching with hot phosphoric acid, such a method is used for removing the separation layer 13 and producing in this manner the level difference indicated in FIG. 5A between the top 20 of the element 18a conductive filling material of the contact opening and the level 21 of the insulating layer 12. By controlling on the one hand the time of prolongation of the etching treatment of the layer of conductive material 18 and on the other hand the thickness of the separation layer 13, if can readily be ensured that the level 20 of the element 18a of conductive filling material is equal to the level of the surface 21 of the insulating layer 12 or that this level exceeds the latter level by a small given height. It has in fact been found that in these conditions the most favourable results are obtained with respect to the contact resistance between the elements 18a of conductive filling material and the metallic interconnection layer 22 subsequently deposited on the structure.
The metallic layer 22 is formed, for example, from aluminum or an alloy of aluminum-silicon in a thickness of approximately 1 μm, in which layer the configuration of interconnections is formed by the conventional photomasking and etching methods.
According to another embodiment of the invention, the material used for forming the separation layer 13 is of such a kind that the conductive material 18 can be etched selectively with respect to this separation layer 13. In this case, use is preferably made of aluminum or an alloy of aluminum or of cobalt. At the stage of the method consisting in removing by etching the major part of the conductive material 18, the separation layer 13 then constitutes a blocking layer at the end of this etching step. When the attack of the conductive material 18 is prolonged, the separation layer 13 is not attacked. Therefore, the thickness chosen for this layer can be slightly smaller than in the preceeding embodiment. Thus, a thickness chosen to lie between 50 and 150 nm is particularly suitable. When the separation layer 13 is formed from the aluminum or from an alloy of aluminum, it can be removed selectively with respect to the insulating layer 12 and with respect to the conductive filling material 18 by means of dry etching in a plasma rich in chlorine ions. It can also be realized by wet etching in a mixture of phosphoric acid, acetic acid and nitric acid frequently used by those skilled in the art.
When the separation layer 13 is made of cobalt, in order to eliminate selectively this layer, a wet etching treatment is carried out.
According to a particularly advantageous embodiment of the invention, the selectively of etching the separation layer 13 with respect to the insulating layer 12 is utilized during the step of etching the contact openings 16c. In fact, etching conditions can be chosen in the insulating layer 12 which are such that the separation layer 13 is not attacked and thus serves as an additional mask for etching the contact openings 16c. When the separation layer 13 is made of aluminum or of cobalt and, after having formed an opening 16b in this layer while using a suitable etching step in the presence of the photoresist mask 15 (see FIG. 2), the openings 16c are etched through the insulating layer 12. As indicated above, this etching step is preferably effected by reactive ion etching, the ions employed being rich in cloride, for which etching step the separation layer 13 with its opening 16b constitutes a mask having a higher resistance to this etching step than the photoresist mask 15 itself. The latter may be removed before the contact openings are etched, but it may also be maintained. By using a separation layer 13 as an additional mask for etching the contact openings 16c into the insulating layer 12, the step of etching narrow and deep contact openings like the formation of practically vertical walls of openings is facilitated.
FIG. 3B shows a variation of the embodiment of the method according to the invention. In this variation, the contact openings 16b, 16c are filled with a conductive material by first depositing a thin layer of a titanium-tungsten alloy as an adhesion and covering layer on the whole surface, inclusive of the inner surface of the contact opening 16c, and then by carrying out the deposition of a thick layer 28 of tungsten, which ensures that the contact openings are effectively filled. As indicated above, the tungsten layer 28 is formed by low pressure chemical vapour deposition (LPCVD), while the layer of titanium-tungsten alloy 27 is deposited by cathode sputtering in a thickness of the order of 100 nm.
FIG. 4B corresponds to a subsequent stage of the method equivalent to that of FIG. 4A, in which the reference numerals corresponding to the similar elements are identical.
The major part of the conductive filling material 28 and the adhesion layer 27 have been removed from the surface of the separation layer 13 and only a part 27A and 28A located in the contact openings 16c is formed of these materials. The adhesion layer 27 of titanium-tungsten alloy is etched in the same conditions as the pure tungsten, one etching step following the other during the same plasma etchind operation. The separation layer 13 therefore plays the same part as that described above with reference to FIG. 4A. FIG. 5B illustrates the subsequent stage of the method, which corresponds to that of FIG. 5A, in which the separation layer 13 has been removed, while a metallic interconnection layer 22 is disposed on the structure and is in contact with the local element of conductive material 28a, 27a. As described above, the removal of the separation layer 13 allows again the level 20 of the element 28a of the conductive filling material to be raised with respect to the level 21 of the insulating layer 12. In the variation described with reference to FIGS. 3B and 5B, the separation layer 13 can be formed from one of the materials already mentioned above, i.e. silicon nitride, aluminum, an alloy of aluminm or of cobalt.
The method according to the invention is not limited to the manufacture of a structure of interconnections on an integrated circuit comprising a MOS transistor; it has more generally for its object to form contacts on any kind of semiconductor device when contact zones and contact openings of very small dimensions should be used.
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A method of the kind consisting in that a contact is obtained with an active zone (11) carried by a semiconductor substrate (10) by means of conductive contact studs (18a) located in the contact openings (16c) of an isolating layer (12) and in that then a metallic configuration of interconnections (22) is formed establishing the conductive connection with the conductive contact studs (18a). A separation layer (13) is provided between the isolating layer (12) and the conductive layer (18), which can be eliminated selectively with respect to the isolating layer (12). Thus, the isolating layer (12) retains its original flatness and the conductive contact studs (18a) have an upper level (20) exceeding slightly the level (21) of the isolating layer (12), thus favoring the contact between these contact studs (18a) and the metallic configuration of interconnections (22). Application in microcircuits having a high integration density.
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BACKGROUND OF THE INVENTION
The present invention generally relates to portable game boards on which various card games may be played outdoors under windy conditions, while preventing cards placed on the board surface from blowing away. More particularly, the board has a plurality of card engaging members capable of releasably holding a number of playing cards, with each of such members being releasably secured to the upper surface of said board in a number of different locations and at a generally infinite number of orientations relative to the edges of the board.
Heretofore, a variety of game boards have been invented for the purpose of facilitating the playing of cards out doors under even windy conditions. However, the boards of the prior art have a number of defects and shortcomings which are overcome by the present invention. By way of example, Hatley U.S. Pat. No. 3,635,478 discloses a board with a plurality of spring arms releasably attached to the board and whose distal ends are urged towards the board and adapted to hold one or a number of playing cards between the ends of the arms and the upper surface of the board. The spring arms may be moved, but only to a limited number of specifically oriented positions on the board.
Similarly, Zirin U.S. Pat. No. 2,453,292 provides resilient card holding clips which may be moved to a number of discrete predetermined locations on the board, but cannot be universally positioned and oriented to better accommodate various games and various number of players.
Other prior art references disclose card boards for holding cards in a number of different ways, such as magnetically or in some form of non-movable or fixed strips.
SUMMARY OF THE INVENTION
The present invention provides a game board which can be folded for storage and opened to provide an upper relatively flat or planar surface on which any number of card games can be played.
To prevent cards placed on such upper surface from blowing away under windy conditions, a plurality of card retaining clips are provided which can be releasably secured to substantially any location on said upper surface, and at any desired angular orientation relative to the edges of the board.
In the preferred embodiment, hook and loop portions of Velcro attachments are respectively applied to the upper surface of the board and to the lower surface of the clips, to permit the releasable securing of the clips to the board.
The clips preferably have a flat base position, an intermediate curved portion extending from one end of the clip and an end position resiliently urged towards the upper surface of the base portion so as to hold one or more cards therebetween.
In a folded condition, the upper surface of the board, bearing one of the Velcro attachments is folded upon itself. However, the edges of the board and/or the lower surface of the board (which is exposed when the board is folded) may also have similar Velcro attachments affixed thereto so that the clips may be conveniently attached to the board when the board is stored or transported. Also, the Velcro attachments may be used as a means for hingedly connecting two parts of the board for folding, and for releasably securing the boards in a folded condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the game board of the present invention in its open operative position.
FIG. 2 is a perspective view of the game board of the invention in its folded inoperative position.
FIG. 3 is a perspective view of one type of card engaging clip for holding a limited number of cards.
FIG. 4 is a perspective view of a second type of card engaging clip for holding a larger number of cards.
FIG. 5 is a perspective view of the game board with both types of clips in selected positions on the board releasably holding one or more cards.
FIG. 6 is a cross section view taken substantially along line 6 — 6 of FIG. 5 and on an enlarged scale.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The game board 10 of the present invention includes a generally rigid, form-retaining base member 12 formed of wood, pressed board, metal, plastic, or the like, and has a substantially flat coplanar upper surface 14 and a substantially flat coplanar lower surface 16 . In its preferred form, the base member 12 , in its operative or playing condition, is of generally rectangular shape having side edge portions 18 , and end edge portions 20 . The member 12 could have other shapes, such as circular, square, polygonal, or the like, but for reasons to be hereinafter discussed, it is preferred that the base member 12 have a center symmetrically disposed fold line 22 along which the base may be folded in half, with the upper surface 14 of the two halves or sections comprising the base member, folding against each other and with the respective side and end edges being in general alignment.
With a rectangular shaped configuration, the corners are preferably rounded as indicated at 23 to avoid sharp corners and to present a more aesthetic appearance.
Suitable protective trims, such as half round moldings 24 may be placed along the side and end edges of the corners of the board.
FIGS. 1, 5 , and 6 illustrate the base member 12 in its open or operative condition. FIG. 2 shows the base member in its folded condition for carrying, storage, or the like. The manner of folding the two sections and securing them in such a folded condition will be later discussed in more detail.
The game board 10 comprises one portion of the present invention, and the other portion consists of one or more clips 28 which may be releasably attached to the upper surface of the game board in any desired position relative to the edges and ends of the board, and in any desired angular orientation relative to such edges and ends. The clips are adapted to releasably hold one or more playing cards which otherwise would be placed on the board and be subject to windy conditions causing the cards to be blown away.
The clips 28 are of generally conventional design and may be purchased at most stationery stores. Each clip includes a lower flat base section 30 of generally rectangular configuration having a medial curved section 32 and a distal end section 34 extending back over the base section, with the section 34 being resiliently urged towards the base section by the nature of the curved medial section 32 . With this type of clip, one or more playing cards 36 may be inserted between the sections 30 and 34 and held therebetween. When it is believed that a large number of cards are to be releasably held by a clip, the latter may be of the type 40 , shown in FIG. 4, similar to clip 28 , but with the end section 44 normally spaced from the base section 46 so as to accommodate, for example, a full deck of cards 48 . The medial portion 50 will still cause the section 44 to be urged towards the base section so as to hold the stack of cards in place.
The clips and the board are constructed so that any required number of the clips can be releasably secured to the upper surface of the board so as to position one or more cards, or a deck of cards, at substantially any desired location and at any desired angular orientation. The exact number of clips and their location and orientation on the board will depend on the particular card game being played. For example, if two persons are playing gin rummy, it may be desirable to have two clips near the center of the board one for holding undealt cards which may be drawn one at a time by the players, and the other for holding discards. It may also be desired to have one clip adjacent each end of the board to receive the cards initially dealt to each player. If bridge is being played, there would normally be four players, and it may be desirable to place a clip adjacent each side and edge of the board for the dealt cards and additional clips for receiving the cards being played.
The manner of attaching the clips to the board will now be described. In general, the lower surface 60 of the base section of each clip and the upper surface 14 of the game board are respectively provided with hook positions and loop portions of fastening material commercialized under the trademark or trade name VELCRO. As shown, substantially the entire upper surface 14 of the board is covered with a sheet 62 of loop elements of one such Velcro fasteners and the lower surface 60 of each clip is covered, at least in part, by a sheet 64 of the hook elements of the other Velcro fasteners. Thus, each clip can be releasably attached to the board in substantially any location and in any angular disposition. The hook and loop positions can obviously be reversed.
Although the upper surface of the board is illustrated as being the Velcro loop fastener sheet 62 substantially covering such surface, it is clearly within the scope of this invention to have the Velcro material 62 placed in spaced strips or the like, or in small patches in only selected positions on the board where the clips 28 or 40 are likely to be deployed.
At the fold line 22 where the two sections of the game board meet, the looped Velcro fastener sheet 62 on one section overlies its edges at 68 and continues down and around the lower surface 16 of the board at 70 . The Velcro fastener sheet 62 on the adjacent section terminates short of the fold line. A hooked or complementary Velcro sheet 72 covers the edge of each adjacent section and a short portion of the upper and lower surfaces of each section. In this manner, the two sections are not only attached to each other by the interaction of the loop and hook elements on the Velcro sheets 68 and 72 , but such connection also permits the two sections to be pivotally movable between an open and folded condition. The sheet 72 may be attached to its board by adhesive or any other suitable means.
Preferably, the edge and end positions of the board are also covered with the loop Velcro elements 74 so that in its folded condition, the clips may be attached to such edges for storage or carrying purposes when the board is not being used.
Also, if desired, one or more small sections of looped Velcro elements 76 can be secured to the lower surface 16 of the board 9 , (which becomes the exposed surface when the sections are folded) on which clips can also be placed for storage, including a clip capable of holding a deck of cards.
To releasably hold the sections in their folded or stored position, a small section 78 of a looped Velcro element can be secured to a lower surface 16 of one section, and a strip 80 of a hook Velcro element secured to the other base section for releasable attachment to the loop element 78 .
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A portable board or platform for playing cards outdoors where wind might blow away cards. A plurality of card engaging members may be placed in any orientation on the playing surface of the board to accommodate a number of cards at selected locations on the platform. The members are releasably secured to the platform by means of hook and loop Velcro type elements, placed on the platform and on the card engaging members respectively.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a safety device for a foldable two-section chute system of a concrete mixing truck. In particular, the present invention relates to a blocking member positionable between adjacent ends of two chute sections when the chute system is transitioning from a folded position to an unfolded position.
[0002] Concrete mixing trucks are a common sight on the roads and at construction sites. FIG. 1 depicts a typical concrete mixing truck 10 used to transport, mix, and pour concrete. The concrete mixing truck 10 comprises a rotatable drum 12 connected to the frame of the truck 10 . The rotatable drum 12 has an outlet 14 directed towards a two-section chute system 16 comprised of a first chute section 18 and a second chute section 20 . The first chute section 18 has a first end 22 and a second end 24 . The first end 22 of the first chute section 18 is pivotally connected to the concrete mixing truck 10 . The second end 24 of the first chute section 18 is connected to a hydraulic cylinder 26 that is attached to the frame of the truck 10 . The second chute section 20 has a first end 28 opposing the second end 24 of the first chute section 18 . The first chute section 18 and the second chute section 20 are attached by a pivotal connection 30 located at top edges 32 , 34 of chute sections 18 , 20 , respectively, adjacent to the second end 24 of the first chute section 18 and the first end 28 of the second chute section 20 .
[0003] The two chute sections 18 , 20 are traditionally capable of being in either a folded position or an unfolded position. During transport, the chute sections 18 , 20 are placed in the folded position with the second chute section 20 resting on top of the first chute section 18 as shown in FIG. 1. When the concrete is ready for pouring, the second chute section 20 is rotated about the pivotal connection 30 until the second end 24 of the first chute section 18 and the first end 28 of the second chute section 20 make contact. The hydraulic cylinder 26 aligns the unfolded two-section chute system 16 with the desired location for pouring concrete. Concrete in the rotatable drum 12 is moved through the outlet 14 onto the chute system 16 .
[0004] One of the problems related to the two-section chute system of concrete mixing trucks occurs when the second chute section is in the process of unfolding. To move from the folded position to the unfolded position, the second chute section is initially manually rotated to an angle sufficient to allow the second chute section to continue rotating by gravity into the final unfolded position. The two-section chute system is in the final unfolded position when the opposing end of the second chute section abuts the opposing end of the first chute section and the second chute section is forced to stop its rotation. The weight of the second chute section, combined with the momentum of the second chute section from the gravitational rotation, can cause injury to a person working alongside a concrete mixing truck in the event the person has a body part located between the opposing edges of the two chute sections. If a person is unaware that the second chute section is being unfolded, the person may not be able to remove the body part from the contact area of the two chute sections in time to avoid injury. It is thus desirable to improve the safety of two-section chute systems.
BRIEF SUMMARY OF THE INVENTION
[0005] The spacing device of the present invention prevents unintended contact between two pivotally attached chute sections of a concrete mixing truck, where the first chute section comprises an annular flange adjacent to a second end of the first chute section and the second chute section comprises an arcuate edge configured to contact the annular flange of the first chute section. The spacing device comprises a mounting flange connected adjacent to the second end of the first chute section and a blocking member connected to the mounting flange. The blocking member comprises a contact surface that is spaced from the annular flange and positioned to contact a portion of the arcuate edge of the second chute section when the blocking member is in a blocking position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a perspective view of a concrete mixing truck with a two-section chute system known in the art.
[0007] [0007]FIG. 2 is a perspective view of a two-section chute system in a folded position showing the spacing device of the present invention.
[0008] [0008]FIG. 3 is a side view of a two-section chute system in a partially open position showing the spacing device of the present invention.
[0009] [0009]FIG. 4 is an enlarged side view of a two-section chute system showing the spacing device of the present invention.
[0010] [0010]FIG. 5 is an enlarged perspective view of an end portion of a first chute section with the spacing device of the present invention in a blocking position.
[0011] [0011]FIG. 6 is an enlarged perspective view of opposing portions of the first and second chute sections with the spacing device of the present invention in a non-blocking position.
[0012] [0012]FIG. 7 is an enlarged perspective view of the front facing side of the spacing device of the present invention.
[0013] [0013]FIG. 8 is an enlarged perspective view of an end portion of the first chute section with a second embodiment of the spacing device of the present invention in a blocking position.
[0014] While the above-identified drawing figures set forth preferred embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the present invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention. It should be specifically noted that the figures have not been drawn to scale, as it has been necessary to enlarge certain portions for clarity.
DETAILED DESCRIPTION
[0015] To better illustrate the spacing device 36 of the present invention, FIG. 2 is an enlarged perspective view of the two-section chute system 16 shown in FIG. 1. The first chute section 18 is comprised of an elongated arcuate wall 38 that terminates in an arcuate edge 40 at second end 24 . The arcuate wall 38 of the first chute section 18 has a diameter D1 at the second end 24 adjacent to the pivotal connection 30 . An annular flange 42 is connected to an outer surface 44 of the arcuate wall 38 adjacent to the arcuate edge 40 of the first chute section 18 . The second chute section 20 is comprised of an elongated arcuate wall 46 that terminates in an annular, arcuate edge 48 at the first end 28 . The arcuate wall 46 of the second chute section 20 has a diameter D2 at the first end 28 adjacent to the pivotal connection 30 . The diameter D2 of the second chute section 20 is slightly greater than the diameter D1 of the first chute section 18 .
[0016] The pivotal connection 30 is formed by a hinge 50 that connects the top edge 32 of the first chute section 18 to the top edge 34 of the second chute section 20 near the arcuate edges 40 , 48 . In the transition from the folded position to the unfolded position, the second chute section 20 is rotated about the hinge 50 . Because the diameter D2 of the arcuate wall 46 of the second chute section 20 is greater than the diameter D1 of the arcuate wall 38 of the first chute section 18 , an inner surface portion 52 of the second chute section 20 overlaps the outer surface portion 44 of the first chute section 18 when the chute sections 18 , 20 are in a fully unfolded position. In the unfolded position, arcuate edge 48 of the second chute section 20 engages annular flange 42 of the first chute section 18 .
[0017] To prevent the arcuate edge 48 of the second chute section 20 from uncontrollably coming into contact with the annular flange 42 of the first chute section 18 during the unfolding process, a spacing device 36 is connected to the chute system 16 . In one embodiment, the spacing device 36 is mounted to the annular flange 42 of the first chute section 18 near the hinge 50 . The spacing device 36 is comprised of a blocking member 54 with a contact surface 56 that is spaced rearwardly from the annular flange 42 of the first chute section 18 . The contact surface 56 of the blocking member 54 is positioned to make contact with a portion of the arcuate edge 48 of the second chute section 20 when the spacing device 36 is in a blocking position. The chute sections 18 , 20 , hinge 50 , and spacing device 36 each are formed from a heavy metal material.
[0018] [0018]FIGS. 3 and 4 are side views of the spacing device 36 in the blocking position. As shown in FIG. 3, spacing device 36 is located on first chute section 18 so as to prevent second chute section 20 from fully unfolding. Thus, spacing device 36 engages arcuate edge 48 of second chute section 20 at a point spaced from annular flange 42 . As shown in greater detail in FIG. 4, the spacing device 36 is positioned between the annular flange 42 of the first chute section 18 and the arcuate edge 48 of the second chute section 20 . As the second chute section 20 unfolds about the hinge 50 , the contact surface 56 of blocking member 54 is axially aligned with a portion of the arcuate edge 48 of the second chute section 20 , preventing engagement between the arcuate edge 48 of the second chute section 20 and the annular flange 42 of the first chute section 18 . The angle formed by the spacing device 36 while in the blocking position is a function of the angle of the contact surface 56 and is selected to create a gap G of sufficient size to prevent harmful contact of second chute section 20 against a person's extremities.
[0019] Spacing device 36 is urged towards the blocking position by a biasing means, which in one embodiment comprises an elongated coil spring 58 . Other biasing structures can be used without departing from the intended scope of the invention, as will be evident to those skilled in the art. The elongated coil spring 58 has a first end 60 and a second end 62 . The first end 60 of the coil spring 58 is connected to the second end 24 of the first chute section 18 . The second end 62 of the coil spring 58 is connected to the blocking member 54 . By way of a non-limiting example, the first and second ends 60 , 62 of the coil spring 58 are connected to the second end 24 of the first chute section 18 and the blocking member 54 , respectively, by eye-bolts 64 , 66 .
[0020] [0020]FIG. 5 is an enlarged perspective view of a portion of the second end 24 of the first chute section 18 with blocking member 54 in the blocking position. In one preferred embodiment, the blocking member 54 comprises first and second plates 68 , 70 . The first plate 68 has a first end 72 and a second end 74 , and a first edge 76 and a second edge 78 . The first plate 68 is pivotally attached to a mounting flange 80 by a pivotal connection 82 . A handle 84 is connected to the first edge 76 of the first plate 68 . The handle 84 extends in the same plane as the first plate 68 and away from the arcuate wall 38 of the first chute section 18 . A protrusion 86 is connected to the second edge 78 of the first plate 68 at second end 74 . The protrusion 86 extends in the same plane as the first plate 68 and towards the arcuate wall 38 of the first chute section 18 .
[0021] The phantom illustration of FIG. 5 shows the inner sidelong portion of blocking member 54 . The protrusion 86 of the first plate 68 contacts the arcuate wall 38 of the first chute section 18 and helps align the contact surface 56 of the blocking member 54 with the arcuate edge 48 of the second chute section 20 when the spacing device 36 is in the blocking position. When in the blocking position, protrusion 86 is positioned to engage the outer surface 44 of the arcuate wall 38 of the first chute section 18 , adjacent to the annular flange 42 . Although FIG. 5 depicts the protrusion 86 at the second end 74 of the second edge 78 of the first plate 68 , the protrusion 86 can be located at other areas along the second edge 78 of the first plate 68 without departing from the intended scope of the invention, as will be evident to those skilled in the art. The length of protrusion 86 is designed to space the blocking member 54 at a distance from the arcuate wall 38 of the first chute section 18 such that the contact surface 56 of the blocking member 54 is axially aligned with the arcuate edge 48 of the second chute section 20 . Thus, when the second chute section 20 is unfolding, the arcuate edge 48 of the second chute section 20 will engage the contact surface 56 of the blocking member 54 , preventing unintentional abutment of the first and second chute sections 18 , 20 .
[0022] The second plate 70 has a first end 88 and a second end 90 , and a first edge 92 and a second edge 94 . The first edge 92 of the second plate 70 is connected transversely to the first plate 68 , such as by welding, adjacent to the second edge 78 of the first plate 68 , forming a right angle between the first plate 68 and the second plate 70 . The second edge 94 of the second plate 70 comprises the angled contact surface 56 of the blocking member 54 . Both first and second plates 68 , 70 are formed from a metal, such as ASTM A 36 plate steel having a wall thickness of about 0.375 inches. In one preferred embodiment blocking member 54 has a height of about 4.50 inches, with contact surface 56 sloping at an angle of about 20 degrees relative to first plate 68 . For this preferred embodiment, the maximum width of second plate 70 relative to first plate 68 is about 2.50 inches.
[0023] The pivotal connection 82 connects the blocking member 54 to the mounting flange 80 . Although FIG. 5 depicts the pivotal connection 82 of the blocking member 54 to the mounting flange 80 at the first end 72 of the first plate 68 , the pivotal connection 82 can be located at other areas of the first plate 68 without departing from the intended scope of the invention, as will be evident to those skilled in the art. The pivotal connection 82 allows the blocking member 54 to shift between the blocking and non-blocking positions. By way of a non-limiting example, the pivotal connection 82 of the blocking member 54 to the mounting flange 80 is formed by a nut and bolt connection 96 .
[0024] While the blocking member 54 of the present invention is comprised of first and second plates 68 , 70 , there are other forms that the blocking member 54 can take without departing from the intended scope of the invention, as will be evident to those skilled in the art. By way of a non-limiting example, the blocking member 54 may be comprised of a solid block of material with the pivotal connection 82 of the blocking member 54 to the mounting flange 80 located at an aperture extending through the entire length of the block. Alternatively, the blocking member 54 may be comprised of a solid block of material with the pivotal connection of the blocking member 54 to the mounting flange 80 located at a mortise section of the blocking member 54 .
[0025] [0025]FIG. 6 is an enlarged perspective view of blocking member 54 that has been pivoted out of the blocking position. The mounting flange 80 of spacing device 36 connects the blocking member 54 to the first chute section 18 . The mounting flange 80 is connected to the first chute section 18 adjacent to the arcuate edge 40 of the first chute section 18 and near the top edge 32 of the first chute section 18 . In one preferred embodiment, the mounting flange 80 is connected to the annular flange 42 of the first chute section 18 proximate to the top edge 32 of the first chute section 18 . The mounting flange 80 is formed from a metal, such as plate steel, like first and second plates 68 , 70 .
[0026] Blocking member 54 is pivoted from the blocking position to the non-blocking position by pulling on the handle 84 to pivot blocking member 54 until the contact surface 56 no longer engages the arcuate edge 48 of the second chute section 20 . As a result, the inner surface portion 52 of the arcuate wall 46 of the second chute section 20 is allowed to overlap the outer surface 44 of the arcuate wall 38 of the first chute section 18 , allowing the arcuate edge 48 of the second chute section 20 to engage the annular flange 42 of the first chute section 18 .
[0027] [0027]FIG. 7 is an enlarged perspective view of the front facing side of spacing device 36 in a non-blocking position. When it is confirmed that no body extremities are located between the first and second chute sections 18 , 20 , the blocking member 54 is pivoted away from the arcuate wall 38 of the first chute section 18 about the nut and bolt connection 96 . As the blocking member 54 is pivoted away from the first chute section 18 , the elongated coil spring 58 is stressed. With the spacing device 36 in the non-blocking position, the second chute section 20 completes the gravitational rotation about the hinge 50 and the arcuate edge 48 of the second chute section 20 engages the annular flange 42 of the first chute section 18 . When the two-section chute system 16 is in the fully unfolded position, the protrusion 86 of the first plate 68 rests against the first end 28 of the second chute section 20 . When the second chute section 20 is rotated back about hinge 50 to the folded position, blocking member 54 is urged back to the blocking position by elongated coil spring 58 .
[0028] The pivotal connection 82 of the blocking member 54 to the annular flange 42 offers an easy and reliable operation of spacing device 36 . In the event concrete slurry contacts the pivotal connection 82 , it is still able to reliably align blocking member 54 with the arcuate edge 48 of the second chute section 20 . The constant pivoting motion of the blocking member 54 between the non-blocking and blocking positions loosens and clears concrete fines or other foreign matter contacting spacing device 36 . Protrusion 86 provides a visual means for confirming that blocking member 54 has been fully returned to the blocking position and that it is ready for spacing the chute sections 18 , 20 in a subsequent unfolding process.
[0029] [0029]FIG. 8 is an enlarged perspective view of a portion of the second end 24 of the first chute section 18 with blocking member 54 in the blocking position. The first and second plates 68 , 70 , pivotal connection 82 and protrusion 86 of FIG. 8 are identical to the first and second plates 68 , 70 , pivotal connection 82 and protrusion 86 described in FIG. 5. According to the embodiment of FIG. 8, a weighted arm 98 replaces handle 84 and elongated coil spring 58 of the embodiment of FIG. 5. The weighted arm 98 has a first end 100 and a second end 102 . The first end 100 of weighted arm 98 is connected to a lower corner 101 at the second end 74 of the first plate 68 . The weighted arm 98 extends at a predetermined angle in the same plane as the first plate 68 and away from the arcuate wall 38 of the first chute section 18 . The weighted arm 98 extends at an angle greater than 90 degrees and less than 180 degrees from the first edge 76 of the first plate. In one preferred embodiment, weighted arm extends at an angle of about 135 degrees relative to the first edge 76 of the first plate 68 .
[0030] The second end 102 of weighted arm 98 is bulbous and comprises a sufficient weight to return the blocking member 54 to the blocking position by gravity. In a preferred embodiment, the weighted arm 98 is 5.00 inches in length and has a weight of about 0.90 pounds with a center of gravity about 3.50 inches from the point of attachment of the first end 100 to the blocking member 54 . Arm 98 is made of a metal material.
[0031] The weighted arm 98 of blocking member 54 offers a simple and reliable means of urging the blocking member 54 to the blocking position. In the event concrete slurry contacts the spacing device 36 , the weighted arm 98 is still able to reliably align blocking member 54 with the arcuate edge 48 of the second chute section 20 . The weighted arm 98 relies on gravity alone to pivot the blocking member 54 about the pivotal connection 82 of the blocking member 54 to the mounting flange 80 back to the blocking position. As previously mentioned in FIG. 7, the constant pivoting motion of the blocking member 54 between the non-blocking and blocking positions loosens and clears concrete fines or other foreign matter from contacting spacing device 36 . The spacing device 36 of FIG. 8 does not rely on any other movable members to return the blocking member 54 to the blocking position. After the blocking member 54 has been pivoted about pivotal connection 82 , protrusion 86 provides a visual means for confirming that blocking member 54 has been fully returned to the blocking position.
[0032] A spacing device of the present invention includes a blocking member that is pivotally attached to a flange mounted adjacent to an end of a first chute section. The blocking member provides a contact surface that engages an arcuate edge of a second pivotally attached chute section when the blocking member is in a blocking position and the second chute section is being unfolded. The contact surface of the blocking member spaces the opposing ends of the chute sections at a predetermined angle, preventing unintentional or uncontrolled contact between the first and second chute sections. When it is confirmed that it is safe to allow the arcuate edge of the second chute section to fully engage the first chute section, the blocking member is pivoted from the blocking position, thereby allowing the second chute section to complete the unfolding process.
[0033] 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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The spacing device mounted to a two-section chute system prevents inadvertent contact between the two chute sections. The spacing device includes a mounting flange and a blocking member positionable between first and second pivotally attached chute sections of a concrete mixing truck. The first chute section comprises an annular flange that is configured to contact an arcuate edge of the second chute section. The mounting flange is connected to a second end of the first chute section and the blocking member is attached to the mounting flange. The blocking member comprises a contact surface that is configured to engage a portion of the arcuate edge of the second chute section when the spacing device is in a blocking position. In the blocking position, the spacing device holds the first and second chute sections in a partially open position to prevent unintended contact between the chute sections.
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BACKGROUND OF THE INVENTION
This invention relates to seat belt retractors. Due to safety regulations, substantial improvements have been made in the structural design of such devices. Normally, they include spools or spring biased reels which payout a safety webbing about a passenger and simultaneously facilitate his comfortable movement in the buckled position. Further, these safety webbing devices have the capability to sense and lock against webbing payout in the event of a collision or overturning of the vehicle, and this capability is usually accomplished through the use of webbing sensitive lock or a vehicle sensitive lock.
The webbing sensitive locks are illustrated by U.S. Pat. No. 3,450,368, and may employ a rotational spring biased centrifugal counterweight to measure the rate of webbing payout and lock the unit when the rotational force on the counterweight exceeds the associated spring bias. The vehicle deceleration locks may be illustrated by U.S. Pat. No. 3,578,260, in which a pendulum, pivoted by a rapid deceleration, locks the webbing against further payout. Moreover, as in U.S. Pat. No. 3,819,126 both systems have been incorporated into a single retraction device. The device of that patent includes only one locking pawl operable by either a vehicle sensitive or a webbing sensitive actuator. Movement of the pawl toward a locking position may be initiated by whichever sensor first reacts to a change in vehicle condition. Should that movement fail to lock up the reel, there is no reserve function available to accomplish locking of the reel. These prior devices do not, however, provide the safest assurance and simple design of the instant invention.
SUMMARY OF THE INVENTION
In order to provide a seat belt retractor which positively locks against webbing payout in the event of a collision, the instant invention includes a seat belt retractor having a base journaling a webbing reel which pays out webbing. Constrained for rotation with this reel are ratchet gears at each end thereof which cooperate with a separate locking pawl of a webbing sensitive lock and a deceleration sensitive lock.
Each lock is complete within itself, and is mounted on the base in a simple manner to insure non-interference with the other lock. Moreover, the use of two locks each having a separate locking pawl provides adequate assurance that at least one will engage, in spite of the possibility that one bar may strike the top of the ratchet gears and bounce off without engagement. Preferably the locks are sensitive to different rates of vehicle deceleration to provide initiation of the independent locking functions in a timed sequence. Preferably the vehicle sensitive lock initiates its locking function at a vehicle deceleration rate which is lower than the vehicle deceleration rate necessary to initiate the webbing acceleration sensitive lock. Should the vehicle sensitive lock fail due to misengagement of the locking pawl and rachet wheel, continued deceleration of the vehicle would cause an increase in the rate of webbing payout due to the forces acting on the wearer. The resultant increase in webbing acceleration in turn causes initiation of the independent webbing sensitive lock. Since two separate pawls are utilized, the pawl associated with the webbing sensitive lock is unaffected by the misengagement which occurs between the ratchet wheel and the pawl associated with the vehicle sensitive lock.
Accordingly, it is an object of my invention to provide a seat belt retractor having dual locking devices responding to a vehicle accident. Moreover, it is an object of this invention to assemble such dual locking devices on a seat belt retractor in a simple, economical design facilitating assembly and eliminating the possibility of interference between the locks and the ratchet gears. More importantly, it is an object of my invention to provide a seat belt retractor, which, in the event of collision, will positively result in a lockup to hold the vehicle passenger in a safe restrained position.
DESCRIPTION OF THE DRAWINGS
The manner in which these and other objects of my invention are attained will be made clear through reference to the following specification and drawings in which:
FIG. 1 is a side elevation view, partially broken away, of a preferred embodiment of my invention, depicting the webbing sensitive lock mechanism;
FIG. 2 is a front elevation of FIG. 1;
FIG. 3 is a plan view of the embodiment of FIG. 1;
FIG. 4 is an exploded perspective view of this preferred embodiment;
FIG. 5 is a perspective view of the vehicle deceleration lock of the preferred embodiment of my invention;
FIG. 6 is a plan view of the deceleration sensor of FIG. 5.
DETAILED DESCRIPTION
Referring primarily to FIG. 4 of the drawings, the seat belt retractor of my invention is assembled upon a base frame 10, having back section 12 and two upstanding flanges or side plates 14 and 16.
The base 12 is formed with a hole 13 for installing the safety webbing take-up means on a seat or at any other suitable position in a vehicle such as an automobile by a suitable fastening member (not shown). The flanges or side plates 14 and 16 of the frame 10 are formed with respective bearing holes facing each other to journal or rotatably supporting a webbing reel 18 therein. This reel 18 may comprise a shaft 20, flanges 22 and 24, secured thereto and an integral sleeve 26, all constrained for rotation as a unit. Preferably bushings 27a and 27b journal shaft 20 in the plates 14 and 16.
The sleeve 26 may have a C-shaped cross-sectional profile providing an axial slot or opening 28 to receive an end portion 29 of a webbing 30 for attachment to the shaft in a well-known manner. The webbing 30 is attached at one end to the shaft such that it will not be detached therefrom and is wound on the sleeve 26 between opposite side flanges 22 and 24. About the periphery of each of these flanges is formed ratchet gears 22a and 24a, facing in the same direction.
The reel 18 and its webbing 30 is spring biased by a spiral spring 32 towards a take up or retracted position. This spiral spring 32 has its outer end secured to a spring cover 34 mounted upon side plate 14 and has its inner end secured in a slot 36 provided in the corresponding end of the shaft 20 so as to bias the reel 18 in a take up direction. The free end of the webbing 30 carries a latch for coupling to a buckle (not shown).
An end of the shaft 20 extending outwardly of the side plate 16 is a notched portion 38 on which is mounted a disc 40 constrained for rotation with the shaft 20 and sleeve 26. The disc 40 is provided with an eccentric integral boss 41 upon which is pivotally mounted a semi-circular inertial member or counter balance 42 whose center of gravity is located within the boss 41. An abutment 44 is formed on disc 40 adjacent to one end of the inertia member 42, so as to permit relative pivotal movement of member 42 only in the opposite direction.
The member 42 is biased against abutment 44 by a spring 50. The spring is connected to the member 42 intermediate the abutment 44 and boss 41 and anchored to disc 40 upon a boss 43. A plate 46 is connected to the end 48 of the shaft 20. It includes extensions which overlie the boss 41 and the boss 43 to retain the components in place.
As long as the angular acceleration of the shaft 20 is within a predetermined value established by the bias of spring 50, the counterbalance 42 remains in abutting relation to boss 44. However, if the webbing payout acceleration is above a predetermined value, the inertia causes rotation of counterbalance 42 relative the shaft 20 against the biasing force of the coil spring 50, resulting in radial movement of a tooth 52 formed on member 42. This tooth 52 then engages a circular cup member 54 rotatably mounted on a hub portion of the disc 40 and has an outwardly open cylinder portion 56. The internal surface of cylinder portion 56 is provided with a ratchet gear 58 which is engaged by tooth 52 of the inertia member 42, effecting limited rotation of cup 54. Through a projection 60 extending from the rear side of cup 54, limited rotation of the cup is transmitted to an actuating lever 61 having an aperture receiving the projection. This projection 60 also extends into a slot 62 of flange 16 to limit rotation of cup 54.
The actuating lever 61 is coupled to one end of a lock member 66 which extends through sector-shaped openings 64a and 64b formed in the respective side plates 14 and 16, so that the rotation of the cup member 54 is transmitted through the lever 61, to the lock bar 66.
The lock bar 66 has pawls 68a and 68b facing the respective flanges 22 and 24 such that rotational movement of lever 61 moves these pawls into engagement with the respective ratchet gears 22a and 24b to lock the reel 18 against rotation.
In the normal state, the lock member 66 is held out of engagement of the ratchet gears of the flanges 22 and 24 by a return spring 70 biased between the end lock member 66 and side flange 16.
Accordingly, upon normal webbing payout, the counterweight 42 rotates with reel 18. When, as a result of impact, the passenger's weight causes a rate of payout to exceed a predetermined rate as set by the bias of spring 50, the member 42 pivots about boss 41, radially extending tooth 52 into engagement with the teeth on the internal surface of cup member 54. This cup is then rotated as permitted by slot 62 to affect rotation of the lever 61 and rotational movement of pawls 68a and 68b into locking engagement with flanges 22 and 24. Such precludes further payout and holds the passenger in restrained position.
The internal surface of cup member 54 is provided with the same number of ratchet gear teeth 58 as the ratchet wheels or flanges 22 and 24. The teeth formed on cup member are positioned circumferentially with respect to the teeth 22a and 24a such as to insure movement of the pawl 66 into locking position only when a gap between adjacent teeth is presented to the pawl area.
Once established, at assembly, the above described timed relation between the ratchet gear teeth 58 and flange teeth 22a and 24a is maintained due to the fixed relation between the cup member 54 and the lever 61 which are pivotally interconnected. The cup 54 rotates with the reel 18 only when the tooth 52 engages one of the ratchet gear teeth 54. This rotational movement is then transferred through lever 61 to the pawl or lock bar 66. In this way inadvertent tip-to-tip contact between the locking pawl 66 and the teeth 22a and 24a is precluded.
Also, it is important to note that this webbing sensor is externally mounted on flange 16 and provided with cover 76. This external mounting facilitates incorporation of the vehicle deceleration sensor into the frame 10.
This vehicle deceleration lock is most clearly depicted in FIGS. 4-6. The sensing portion is carried within a housing 80 and comprises a sensing weight 82 having a tubular projection 84 seated on a lower wall of the housing 80. The diameter of this projection 84 defines the deceleration force required to tilt the weight. Preferably this weight should be designed to actuate or tilt prior to actuation of the webbing sensor as will be explained. A protuberance 86 extends into the tube 84 for locating or centering the weight. The weight configuration is such that it has a low centroid so as to facilitate return to the upstanding position.
The top of the acceleration sensing weight 82 is formed with spherical recess 85 which receives a projection 87 depending from a lever 88 rotatably mounted at its center 90. The lever 88 is rotated when the acceleration sensing weight is tilted, as will be described hereinafter. The lever has a substantially symmetrical shape with respect to its support point 90, whereby it can be rotated with a small force exerted upon projection 87 by the inclined surface 85 upon tilting of acceleration sensing weight 82. Also, end of lever 88 remote from the lower projection 86, will strike an abutment 92 of the housing 80 when it is rotated a predetermined extent by tilting of the sensing weight 82. This limitation on rotation prevents excessive tilting of weight 82, thereby facilitating return of the sensing unit to its original position. Above the lever 88 is a ratchet lever 96 pivoted upon pin 98 attached to the side plate 16 of the frame with its lower side resting upon lever 88. The ratchet lever 96 has a gear tooth 100 and rests upon lever 88 by virtue of its weight. However, when the lever 88 is tilted with a vehicle speed change at a rate in excess of a predetermined value, ratchet lever 96 is pivoted upward and brought into a second position such that gear tooth 100 will engage a separate ratchet gear 102 which is mounted adjacent flange 24 and constrained for rotation therewith.
The ratchet lever 96 has a central hole or opening 110 which loosely receives an end of a second lock bar 112 extending through and supported in sector-shaped holes 116a and 116b in the respective side plates 14 and 16. The lock bar 112 is normally held in a position out of engagement with the ratchet gears on the flanges 22 and 24 of the reel 18. However, when the ratchet lever 96 is rotated engagement with the ratchet gear 102, further rotation of reel 18 results in further rotation of ratchet lever 96 with locking bar 112 being moved into locking relationship with the gear teeth of flange 22 and 24. Accordingly, the opening 110 of the ratchet lever 96 and the end portion of the lock bar 112 should be related to each other such that the lock bar is rotated to the locking position when the ratchet lever 96 is rotated by the rotating force of the ratchet gear 102. It should be noted that the locking bar 112 is, however, merely rotated by lever 96, and that the sector shaped holes 116a and 116b still permit abutting force of lock bar 112 to be transmitted to side flanges 14 and 16. As in the case of the lock sensitive to webbing payout, the circumferential relationship of the gear tooth 100, the teeth of ratchet gear 102, and the teeth 22a and 24a of the flanges 22 and 24 is established at assembly such that movement of the locking bar 112 occurs only when the pawls are free to enter between adjacent teeth formed on the flanges. That is, engagement of tooth 100 with gear 102 occurs only at a circumferential position such that pivotal movement of ratchet lever 96 moves pawl bar 112 into the locking position in the gap between adjacent teeth on the flanges 22 and 24. In this way the danger of pawl contact with the tip of teeth 22a and 24a and consequent misengagement is effectively eliminated.
In normal operation, the acceleration sensing weight 82 is held in its upstanding position shown in FIG. 6 so that the ratchet lever 96 is in its position out of engagement with the ratchet gear 102 and lock bar 112 is also out of locking position.
Also, in this state, the webbing can be easily withdrawn or retracted by the passenger's movement against the force of the spiral spring 32. At this time, the inertia member 42 of webbing sensor is rotated in unison with shaft 20.
When the vehicle decelerates at a rate in excess of the predetermined value due to a collision or other causes, the acceleration sensing weight 82 is tilted due to its inertia, thus raising the projection 87 to turn the lever 88 about its support pin 90. As a result, the ratchet lever 96 is rotated about the pin 98 by the end of the lever 88, thus bringing the gear tooth 100 into engagement with the ratchet gear 102.
Meanwhile, with the above acceleration, the passenger bearing the safety webbing experiences a force tending to fling him forward, whereby the webbing is quickly taken out, causing rotation of the reel 18 and ratchet gear 102. Thus, as soon as the ratchet lever 96 engages the ratchet gear 102, it is further rotated, causing the rotation of the lock bar 112 into engagement with the ratchet gears of the flanges 22 and 24 to lock the reel.
Preferably the locking arrangement responsive to the speed of webbing payout, i.e., speed of rotation of the reel 18, is set to be less sensitive than the locking arrangement responsive to changes in vehicle acceleration, i.e., movement of inertial weight 82. In this way the vehicle sensitive locking mechanism will react first. It may be set to operate at the threshold of impact considered to provide maximum passenger safety. The webbing sensitive locking mechanism on the other hand may be set at a higher point of sensitivity to allow for freedom of movement of the passenger and initial payout of the webbing for use without experiencing the annoyance of inadvertent lock-up of the reel.
In the event of failure of the locking bar 112 to lock-up properly with teeth 22a and 24a of the reel 18, the existing impact conditions will cause the passenger to exert further load on the webbing 30 resulting in more rapid webbing payout. The webbing sensitive locking mechanism may then operate to lock the reel 18 and protect the vehicle occupant from injury.
The webbing sensitive mechanism operates to lock-up the reel with a separate pawl bar 66. The earlier misengagenment of the locking bar 112 has no effect on the availability of the webbing sensitive mechanism to lock the reel.
Accordingly, my invention combines a webbing sensitive and vehicle sensing locks into a unique compact retractor providing dual locking safety concept without possible interference between the locks. Common to both locks, is the feature that webbing payout is required to fully actuate each unit. This results even with the vehicle deceleration unit, in that ratchet 102 must rotate lever 96 in order to move the lock bar 112 into holding position. This movement, however, is due to positive engagement between tooth 100 and gear 102 and is not sensitive to the rate of webbing payout. By using separate lock bars, the possibility of precluding lock-up by engaging the tip of the teeth of flanges 22 and 24 is virtually eliminated.
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A seat belt retractor having a dual lock means including a webbing sensitive lock for detecting a rate of webbing payout in excess of a predetermined rate and an impact lock for determining vehicle deceleration in excess of a predetermined rate, each of said locks being independently actuated upon detection of each said excess rate. In a preferred form said locks are actuable at different rates of vehicle deceleration to provide sequential initiation of the independent locking functions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of patent application Ser. No. 08/746,548, filed Nov. 13, 1996, now U.S. Pat. No. 6,007,220.
REFERENCES
1. U.S. Pat. No. 4,089,047 “Trifocal Mirror-Reflector” to Luderitz, May 9, 1978
2. U.S. Pat. No. 4,683,526 “Asymmetric Lamp” to Krogsrad and Jul. 28, 1987
3. U.S. Pat. No. 4,868,727 “Light Fixture With Integral Reflector and Socket Shield” to Ponds and Calloway, Sep. 19, 1989
4. U.S. Pat. No. 4,295,186 “Slit Illuminating Device” Sugiura, Muneharu; Sagara, Seiji, Oct. 13, 1981
5. U.S. Pat. No. 3,492,474 “Reflector With Compound Curvature Reflecting Surface” Yamaguchi, Seiichi; Hishinuma, Satoshi, Jan. 27, 1970
6. Illumination Engineer's Association Handbook
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is an article of manufacture and relates to reflectors, specifically, to a symmetrical reflector in the cross-sectional shape using two hyperbolas and fluorescent light fixtures utilizing such a reflector.
2. Description of Related Art
Other patents have taught how to use reflectors on light fixtures that have a cross-sectional shape generally hyperbolic, generally elliptic, or generally parabolic. For example, Reference 1 uses reflectors with elliptical cross-sections with the feature of one set of foci of the ellipses being coincident and with the other foci located at the ceiling level. These incandescent light fixtures use only reflected light with the embodiment designed such that all direct light coming from the light source is blocked. This patent would restrict the fixture to something small in diameter in order to meet the requirement of having one set of foci coincident. Having all direct light blocked seriously limits the efficiency of the lamp. A hyperbolic reflection surface is added to the lamp in another embodiment that is described, however, no diagram of the configuration is provided and the juxtaposition of the light source and the focus of the hyperbola is not taught.
Reference 2 claims a desk lamp with a reflector in the shape of a parabola formed from a series of triangular facets. This patent claims a method to approximately construct at reasonable cost, a curved reflection surface to improve the light delivery from the lamp.
Reference 3 claims a reflector, curvilinear in cross-sectional shape, and having tabs formed from part of the reflector surface for the purpose of socket protectors. The relative location of the light bulb to the reflector is not taught. Many other necessary features to define the embodiment of the reflector, such as the position of the light bulb relative to the focus of a conic section, is not taught. This embodiment utilizes a 300-watt light bulb, and therefore is not designed for energy savings but as a security lighting fixture.
Reference 4 is a lighting device having a plurality of linear surface mirrors, each partially surrounding a single light source. The reflector approximates an elliptical-shaped reflector. Its purpose is for use in a reproduction machine.
Reference 5 is a three-dimensional concavo-convex reflector for use as a headlamp on an automobile. At least part of the three-dimensional surface is formed having a hyperbolic curvature in the horizontal plane. It has a single light source. No attempt is made to provide energy savings.
Although there are a number of fluorescent light fixtures on the market, few seem to utilize the direct light and reflected light coming from the light source to full advantage. Reflection surfaces are painted milky white that has a medium reflectance. Some reflectors are being made on special order to retrofit existing light fixtures, reduce the number of fluorescent tubes, and thus improve the light efficiency and energy utilization. These retrofit reflectors are fabricated by bending them into rectangular facets thus approximating a parabola in cross-sectional shape. A highly reflective material, such as Silverlux by 3M Company applied to the surface of a thin aluminum sheet, is being used as the material for these reflectors. Since a parabolic reflector directs the light straight downward, the area of illumination between the rows of fixtures is lit only by direct light and receives very little of the reflected light. These installations tend to have a bright area under the fixture and a shadowy, dark area half way between fixtures. This non-uniform distribution of light is objectionable.
Generally, fluorescent light fixtures, which are designed to provide illumination for an area, should:
a. Provide an adequate level of illumination.
b. Uniformly illuminate the area.
c. Minimize the formation of shadows.
d. Provide light agreeable for human activity.
e. Minimize the use of energy while providing an adequate level of illumination.
None of the above mentioned embodiments meet all five of these criteria. Accordingly, there is a need for new, optimized, efficient fluorescent light fixtures that will provide uniform light patterns coupled with an adequate level of illumination, and providing substantial energy savings. They must be suitable for use in new building construction or retrofit to existing structures, for illumination of art works or advertising signs, and for use in homes, stores, and offices.
OBJECTS AND ADVANTAGES
Modern civilization has moved indoors and functions around the clock. Thus, there is a need for low cost lighting in buildings, offices, warehouses, barns, museums, homes, and where ever there is human activity. Electrical rates continue to slowly rise and, as a strategy to cope with these rate increases, conservation is one approach. Because much human activity takes place indoors under artificial light, the light level must be high enough so quality work can be conducted, sporting events well lit, and kitchen areas adequately lit for food preparation. Shadows produced by point sources of light are a nuisance. Similarly, uneven lighting in work areas creates eyestrain. Uneven lighting of advertising displays sacrifices impact. Light and dark areas on paintings or tapestries on exhibit in art museums detracts from the presentation of such artistic works.
Approximately 80% of what human beings learn comes through the sense of sight. Human beings see objects by reflected light. Therefore, it is important that human factors of illumination in a room, office, or other work place, be bright, have good color rendition, and exhibit a character and quality which is most pleasing and agreeable.
Accordingly, it is an object of this invention to provide an occupied area with fluorescent light fixtures which provide an adequate level of illumination while substantially saving energy compared to existing light fixtures. In addition, another object of this invention is to minimize or eliminate shadows and to provide an illuminated area that is lighted in a uniform manner. It is a further object of this invention to provide illumination to an area by light fixtures projecting light that has a most pleasing character and quality.
BRIEF SUMMARY OF THE INVENTION
The law of reflection is the essential physical principle upon which this invention is based. It states:
When an energy wave incident upon a flat or curved surface is reflected, the angles of incidence and of reflection are equal and lie in the same plane.
Various materials and types of surfaces reflect light at a different reflectance. A diffuse surface can reflect 10% to 60% of incident light while a specular surface can reflect 80% to 95% of the incident light. Since high efficiency is desired to achieve energy savings, the surface finish chosen for the reflector is specular. Polished aluminum, polished stainless steel, and a plastic laminate called Silverlux by 3M Company all qualify as possible candidates for reflector surfaces. Material selection for the reflector surface is not limited to this list of materials, others surely also qualify.
A second ingredient needed is the shape of the reflector. The classic shape used in the past for light fixtures with reflectors has been the parabola that is know to reflect the light downward. For this current invention, a hyperbola in a 2-dimensional shape is selected for the reflector. Reference 6 shows the general principle of the use of a hyperbola as a reflector but does not show any embodiment. This cross-sectional shape is selected because the hyperbolic reflector provides a broad diffusing light pattern on the illuminated surface by reflecting the light downward and outward. The axis of the hyperbola can be angled in order to throw the light in a downward and outward direction also. Much of the light from the backside of the fluorescent tube is reflected to a surface that is to be illuminated. Thus, an illuminated surface receives the direct light from the fluorescent tubes plus the light reflected from the reflector.
When a reflector in the shape of a hyperbola is located behind a fluorescent light tube as a light source, and the center of the light source is located coincident with the primary focus of the hyperbola, the reflected light appears to have originated from the other focus, herein referred to as the virtual focus, of the hyperbola. The virtual focus is associated with the unused branch of the hyperbola. It can be shown by mathematical development that the hyperbola precisely matches the law of reflection and can demonstrate the feature of the hyperbolic reflector that the reflected light appears to originate from the virtual focus. See FIG. 1 . In this case the pencil of light rays appear as a fan-shape providing a natural diffusion pattern of reflected light emanating from the virtual focus. Thus, the direct light is a fan of light rays from the primary focus and the reflected light is a fan of light rays from the virtual focus. This dual set of light sources, one above the other, tends to eliminate shadows from objects placed near the light fixture.
The current invention has two fluorescent tubes. Associated with each fluorescent tube is a reflector section in a hyperbolic shape, one reflector section being the mirror image of the other reflector section, where the reflector sections are joined at the centerline at a common edge so the reflector is symmetrical. The common edge is located below a straight line connecting the two primary foci. The central part of the reflector is constructed so as to interrupt the light that would otherwise be directed from one tube to the other, and reflects this light emanating from each fluorescent tube toward the surface to be illuminated. By having the fixture constructed in this arrangement with direct light coming from the two primary foci and reflected light seeming to come from the two virtual foci provides agreeable light uniformly distributed on the surface to be illuminated. This combination also provides for adequate levels of illumination.
As a variation, it is possible to design the light fixture so that the two virtual foci are coincident. In this alternate embodiment, all the reflected light from both the reflector sections seems to come from the coincident virtual foci.
Light fixtures using the reflectors described above, combined with energy-saving fluorescent tubes and electronic ballasts, results in substantial energy savings compared to currently available fluorescent light fixtures while providing an adequate level of illumination. This is achieved by overall improvement in efficiency of the light delivery by the hyperbolically shaped specular reflector and the need for fewer electronic components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general view of reflected light from a hyperbolic reflector.
FIG. 2 shows a symmetrical fluorescent light fixture with two fluorescent tubes where the reflectors are hyperbolic cross-sectional shaped specular reflectors. The non-parallel axes of the reflectors are canted to reflect the light downward and outward.
FIG. 3 shows a symmetrical fluorescent light fixture with two fluorescent tubes where the reflectors are hyperbolic cross-sectional shaped specular reflectors. In this alternate embodiment, the two virtual foci are coincident.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment for this invention is shown in FIG. 2, where a fluorescent light fixture with two connected hyperbolic cross-sectional specular reflector shapes is presented. The axes associated with the hyperbolic reflectors are not parallel.
FIG. 2 presents a light fixture 100 , using two fluorescent light sources 101 and 102 as the preferred embodiment for light fixtures requiring two elongated light sources. Associated with light source 101 is a hyperbolic shaped first reflector section 103 and associated with light source 102 is a hyperbolic shaped second reflector section 104 . Second reflector section 104 is a mirror image of the first reflector section 103 . First reflector section 103 has associated with it a first primary focus 105 and a first virtual focus 107 . Second reflector section 104 has associated with it a second primary focus 106 and a second virtual focus 108 . The center of the light source 101 is located coincident with the first primary focus 105 and the center of light source 102 is located coincident with second primary focus 106 . Straight line 111 is constructed by connecting the first primary focus 105 with the second primary focus 106 . Common edge 110 is located below and on the opposite side of straight line 111 from the fluorescent light sources 101 and 102 . The reflector so formed by joining the first reflector section 103 and the second reflector section 104 at the centerline 109 along a common edge 110 , is termed a dual compound reflector 112 .
Each reflector section 103 and 104 has an axis, first axis AL on the left for the first reflector section 103 , and a second axis AR on the right for the second reflector section 104 . Axis AL is defined as a straight line connecting the first primary focus 105 and the first virtual focus 107 . Axis AR is defined by a straight line connecting the second primary focus 106 and the second virtual focus 108 . First virtual focus 107 and second virtual focus 108 are generally located above the fixture. Axes AL and AR will generally be angled a few degrees relative to the centerline of the fixture such that the axes are nonparallel. The acute angle forming between axis AL and axis AR is termed angle AA.
Each fluorescent light fixture must have a ballast 113 , which is generally located above the reflector and within the fixture, and associated wiring from the ballast to the tubes according to the known art. A translucent cover (not shown) may be added to the fixture. Light fixture 100 comprising the two fluorescent light sources, ballast, wiring, and the dual compound reflector 112 provides illumination to surface 120 .
FIG. 3 presents a light fixture 200 , using two elongated fluorescent light sources 201 and 202 as an alternate embodiment for light fixtures requiring two elongated light sources employing a dual compound hyperbolic reflector. Associated with light source 201 is a hyperbolic shaped first reflector section 203 and associated with light source 202 is a hyperbolic shaped second reflector section 204 . Second reflector section 204 is a mirror image of the first reflector section 203 . First reflector section 203 has associated with it a first primary focus 205 and a first virtual focus 207 . Second reflector section 204 has associated with it a second primary focus 206 and a second virtual focus 208 . The center of the fluorescent light source 201 is located coincident with the first primary focus 205 and the center of fluorescent light source 202 . is located coincident with second primary focus 206 . Straight line 211 is constructed by connecting the first primary focus 205 with the second primary focus 206 . Common edge 210 is located below and on the opposite side of straight line 211 from the light sources 201 and 202 . The reflector so formed by joining the first reflector section and the second reflector section at the centerline 209 along a common edge 210 is termed a dual compound reflector 212 .
Each reflector section 203 and 204 has an axis, first axis AL on the left for the first reflector section 203 , and a second axis AR on the right for the second reflector section 204 . Axis AL is defined as a straight line connecting the first primary focus 205 and the first virtual focus 207 . Axis AR is defined by a straight line connecting the second primary focus 206 and the second virtual focus 208 . First virtual focus 207 and second virtual focus 208 are generally located above the fixture and are coincident. The acute angle forming between axis AL and axis AR is termed angle AA.
Each fluorescent light fixture must have a ballast 213 , which is generally located above the reflector and within the fixture, and provided with associated wiring from the ballast to the tubes according to the known art. A translucent cover (not shown) may be added to the light fixture. Light fixture 200 comprising the two light sources, ballast, wiring, and the dual compound reflector 212 with coincident virtual foci provides illumination to surface 220 .
The foregoing description 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. Obvious modifications or variations are possible in light of the above teachings.
The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims, which are appended.
GLOSSARY
FIG. 2
100 fluorescent light fixture
101 first fluorescent light source
102 second fluorescent light source
103 first reflector section
104 second reflector section
105 first primary focus
106 second primary focus
107 first virtual focus
108 second virtual focus
109 centerline of the light fixture, an axis of symmetry
110 common edge connecting first reflector section and the second reflector section
111 line-of-sight straight line defined by connecting the first primary focus with the second primary focus
112 dual compound reflector
113 ballast
120 illuminated surface
AR first axis
AL second axis
AA angle formed between axis AL and axis AR
FIG. 3
200 fluorescent light fixture
201 first fluorescent light source
202 second fluorescent light source
203 first reflector section
204 second reflector section
205 first primary focus
206 second primary focus
207 first virtual focus
208 second virtual focus
209 centerline of the light fixture, an axis of symmetry
210 common edge connecting first reflector section and the second reflector section
211 line-of-sight straight line defined by connecting the first primary focus with the second primary focus
212 dual compound reflector with coincident virtual foci
213 ballast
220 illuminated surface
AR first axis
AL second axis
AA angle formed between axis AL and axis AR
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A specular dual compound reflector having a cross section in the form of hyperbolas is disclosed. This reflector is combined with energy saving fluorescent tubes and ballast, forming a fluorescent light fixture for the purpose of providing adequate and uniform illumination to a surface, subdue shadows, provide agreeable illumination, and resulting in substantial energy savings. Two similar configurations are disclosed.
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This application is a national phase of International Application No. PCT/GB2007/003198 filed Aug. 21, 2007 and published in the English language.
FIELD OF THE INVENTION
The invention relates to an improved form of dosage dispensing canister and is particularly applicable to multiple-dosage canisters intended to dispense narcotic drugs in spray formulations suitable for sublingual delivery.
Fentanyl and cannabis are two examples of such drugs and their formulation for inhalation, oral lozenge delivery, or a sublingual use is well known. Equally well known are a plurality of approaches to the delivery problem as such. None of these solves the dangers inherent in potent controlled drugs such as those exemplified above whose misuse can lead to undesirable and indeed life-threatening side effects.
State of the Art as Known to the Applicant
Metal canisters are inherently not suitable for narcotic formulations because of the tendency of the canister in the area to corrode with time. Internal coating treatments may prove of use, but these are costly and are not immune to degradation. Metal canisters can also easily be tampered with to drain their contents because their walls are notoriously thin and this is especially the case with pressurised-propellant containing canisters.
Valves with multi polymer/metal springs to give metered dosages are available in various build options but these can require of the order of up to ten or more components. The risks of failure with repeated use are clear. Any metal components again are at risk of attack from the canister contents.
It is especially dangerous to try to package potent narcotic drugs in propellant-driven containers because any failure or puncture of the unit could automatically vent the contents into the room with dangerous and obvious inhalation risk. Furthermore, it is known that the valve assemblies in propellant-driven containers occasionally malfunction, and stick in an open position. This results in a continuous release of product, rather than in a dose-controlled fashion. The dangers of this when the product is a narcotic drug are self-evident.
Non-pressurised pumps attract the same complication objections as valve products. Separate actuators are common but these can be removed or can fall off. They may also cause the product to be sprayed in the wrong direction.
Lock out systems have been proposed by various workers but these are complex and typically incorporate electronic feedback systems, all of which again can go wrong; and whilst multiple dose packs are an attractive sale item in the (illegal) drug market, if anyone stands any reasonable chance of accessing all such pack contents then an inadvertent overdose can quickly follow.
There is finally the issue of priming which overshadows all these known proposals. Many of the proposers of aerosol and pump driven systems offer multi dose models in the belief that the products will hold prime during storage. This is not the case. All packs—in particular those incorporating dip tubes—will lose prime over time and will require up to (say) three actuations to reach the correct dose stated on the packs. The dangers are clear.
SUMMARY OF THE INVENTION
The invention seeks to provide a single-dosage or multi-dosage dispensing canister, especially but not only applicable to the safe dispensing of potent narcotics, in which the risks discussed above are minimised to enable safe measured doses to be administered to patients.
Accordingly, the invention provides a one dose at a time, non-pressurised fluid dispensing canister from which fluid is dispensed as a result of two surfaces of the canister moving, from a non-dispensing starting position, towards one another under the control of a user; said surfaces comprising the respective opposite end region surfaces of a two-portion canister one of whose portions telescopes within the other; characterised in that the canister incorporates a mechanism which, once a first dose has been dispensed, acts to prevent any subsequent attempted movement of the said surfaces into or towards their non-dispensing starting position.
In an alternative embodiment, the invention provides a one dose at a time, non-pressurised fluid dispensing canister from which the or each dose is dispensed as a result of two surfaces of the canister moving towards one another under the control of the user; characterised in that the canister incorporates a mechanism which, once a first dose has been dispensed, automatically prevents any further dispensing movement of the said surfaces (in the case where the canister is a one-dosage only canister) or (where the canister is a multiple-dosage-dispensing canister) allows such movement only after the two surfaces have first been moved in a direction or directions other than that which alone caused the first dose to be dispensed; or after the removal—or after a further dosage-allowing movement—of a portion of the canister has occurred.
Preferably, the surfaces comprise the respective opposite end region surfaces of a two-portion canister one of whose portions telescopes within the other. More preferably, the telescoped canister portions incorporate a one-way ratchet mechanism, which, once they are assembled to form the canister, resists any subsequent attempt to disassemble them. Most preferably, there are multiple engaging ratchet teeth thus allowing a single dose to be dispensed in progressive stages.
In any of these aspects, it is preferable that multiple doses can be dispensed after the first dose by imparting a twist-and-push relative movement to the canister surfaces each time a subsequent dose is desired to be dispensed. Preferably, the last such twist-and-push movement locks the canister portions. More preferably, the last such twist-and-push action either closes the orifice of the canister from which the fluid has been expelled and/or automatically ejects from the canister the orifice—containing portion thereof.
Included within the scope of the invention is a canister substantially as described herein with reference to and as illustrated in any appropriate combination of the accompanying drawings.
Also included within the scope of the invention is a drug dispensing canister constructed as described herein.
The embodiment of the invention to be described herein is especially suitable to sublingual delivery and is deliberately restricted to a dose pack size of two therapeutic doses only. Its design is inherently simple but leak-free and is readily portable, and its contents can be dispensed and directed with accuracy. It incorporates a mechanism which makes it impossible for the second dose to be delivered without first having exhausted the first dosage and then imparting a specific movement to the canister portions before the second dosage will be expelled at all.
The scope of the invention is defined in the claims and one particular embodiment of it will now be described in detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In these drawings:
FIGS. 1 though 6 show a two-dosage container, embodying the invention, in conventional serial orthogonal projectional views in which FIG. 4 is a section along the line a-a of FIG. 3 ;
FIGS. 7 through 12 show similarly conventionally drawn views of a second, one-dosage-only, embodiment of the invention in which FIGS. 10 and 11 are respectively sections along the line A-A of FIG. 9 and the line c-c of FIG. 12 ; and
FIG. 13 is a scrap section detail showing the one-way ratchet mechanism used in either of these embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Both embodiments consist of non-metallic materials and comprise essentially a circular-cylindrical elongated canister whose two half-portions telescope. These canisters are relatively small in size so as to be readily pocketed. Each contains a measured dosage of potent narcotic in fluid form and each is initially sheathed in suitable tamper-evident collar shields which must be removed before any dosage can be dispensed from the canister.
In the two-dosage canister of the FIGS. 1 through 6 the circular-cylindrical top portion 11 of the canister telescopes within the similarly circular-cylindrical bottom portion 12 . The top portion 11 as illustrated in FIG. 4 incorporates a circular-cylindrical chamber 13 into which the narcotic in fluid or powder form is packed. An orifice 14 is positioned adjacent the closed upper end of the top portion 11 of the canister and the canister contents are sprayed through this orifice to the atmosphere via a nozzle when the canister is activated.
The close end face 15 of the bottom portion of the canister is dished, as shown, and locates into an abuts one end of a tubular cylindrical piston rod 16 . A spigot 17 is a push fit inside the end of the tubular piston rod 16 and locates the rod centrally on the recessed dished surface 15 of which the spigot 17 forms an integral protrusion.
The other end of the tubular piston rod 16 locates a piston 18 which is sized, and sealed to be a sliding fluid-tight push fit inside the chamber 13 . The piston 18 when activated therefore acts to expel progressively the narcotic from the chamber 13 out via the orifice and nozzle 14 .
As initially supplied, the orifice and its nozzle are protected by a removable cap 19 and the gap between the radially outermost surface 21 of the canister base portion 12 and the radially outermost surface 22 of the top portion 11 is covered by 2 peelable plastics transparent tamper-evident sealing rings 23 , 24 (shown in chain line in FIG. 5 that removed from each other figure). With the canister contents already packed into the chamber 13 and the piston and piston rod assembly in place, a one-way ratchet mechanism of the kind shown in FIG. 13 constrains the canister halves subsequent to the two halves being assembled.
The radially outermost surface of the bottom canister half 12 is formed with an inward-projecting key tab 23 . This key is a sliding engagement fit in a guide groove 24 formed along the length of a ring 25 which is bonded to the surface of the canister half 11 . The key 23 is of restricted longitudinal depth such that, as the two halves of the canister are brought towards one another by pushing the end face of one half towards the other, the key tab 23 , when it has cleared the groove 24 axially can then move radially along a space 26 defined between the end of the ring 25 and the protruding portion of the canister top half 11 .
That protruding portion is labelled 27 in FIG. 3 of the drawings and it incorporates, as FIGS. 1 and 5 each show, its own longitudinal groove along which the key can again move when properly positioned to enter the groove 28 .
For the key 23 to make these successive movements, it must first be sent along the groove 24 by virtue of the bottom canister half 12 being pushed towards the top canister half 11 as outlined above. The bottom half 12 must then be twisted radially about the top half 11 by 45° to move the key 23 along the defined space 26 and into alignment with another groove 28 . Another axial push on the inface in of the bottom half of canister 12 sends the key 23 along the groove 28 until the radially outermost surface 21 of the canister half 12 is up against the underside of the radially outermost surface 22 of the top canister half 11 .
These two successive movements will of course actuate the piston 18 to expel sequentially two successive doses of fluid from the chamber 13 via the spray-nozzle-containing orifice 14 . The whole design of the canister makes it impossible for the second dosage to be dispensed before the first has been fully dispensed and also prevents the second dosage from being dispensed until after the twist-and-push action has been applied to the bottom canister half 12 .
The one-way ratchet construction has the dual function, firstly of resisting any attempt to pull the two canister halves apart once they have been initially assembled and secondly of effectively locking the canister shut once both doses have been fully dispensed. The two circular-cylindrical canister halves are sufficiently resilient to allow the ratchet teeth to ride over one another in axial relative movement whilst being tough enough to resist at least initial attempts to puncture or break open the canister surfaces.
The protective cap 19 must of course be removed before any dose can be dispensed. As well as having a protective function to prevent dirt entering the nozzle, in preferred embodiments of the device, the cap is a sealing cap to prevent moisture ingress into the device, and to act as an additional safety feature in the unlikely event of leakage of the contents through the valve. The tamper-evident transparent plastics sealing rings 23 and 24 ideally should be removed in sequence 24 followed by 23 , 24 alone being removed to dispense the first dosage and then 23 subsequently being peeled away when the second dosage is ready for dispensation.
The embodiment of FIGS. 8 through 12 differs principally from the one described above in that it is a one-dosage-only dispenser. The tamper sealing cover 29 of this embodiment occupies the whole of the gap between the radially outermost surface 31 of the top canister half and the radially outermost surface 32 of the bottom half. When the tamper seal 29 is broken and peeled off, a single push on the end face 33 of the canister along the central axis thereof dispenses the whole dose in one go.
Other differences seen in the embodiment are, firstly, that the removable cap 34 has a bayonet-style extension 35 and is itself a push fit, not a screw fit, on the dispensing orifice; and the cap is angled at approximately 75° to the central longitudinal axis of the canister, as is the dispensing orifice and nozzle so that an accurately directed dosage spray can be dispensed.
This latter feature is especially useful if the spray is to be sublingually directed and the canister is to be inverted (from the position as shown in the drawings) in order to deliver it.
The scope of the invention is defined in the claims that follow.
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A one dose at a time, non-pressurized fluid dispensing canister from which the or each dose is dispensed as a result of two surfaces ( 21, 22 ) of the canister moving towards one another under the control of the user, wherein the canister incorporates a mechanism which, once a first dose has been dispensed, automatically prevents any further dispensing movement of the surfaces ( 21, 22 ) (in the case where the canister is a one-dosage only canister) or (where the canister is a multiple-dosage-dispensing canister) allows such movement only after the two surfaces ( 21, 22 ) have first been moved in a direction or directions other than that which alone caused the first dose to be dispensed.
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BACKGROUND OF THE INVENTION
This patent application claims foreign priority to South African Patent Application No. 2011/02953, filed 20 Apr. 2011, the disclosure of which is incorporated by reference herein in its entirety. Priority to this application is hereby claimed.
This invention relates to the collection of a barrier which, when deployed, comprises an elongate array of interconnected flexible wire coils.
A barrier of the aforementioned kind is described, for example, in the specification of South African patent No. 98/10149. When inoperative this type of barrier is stored, in a compact form, on a trailer or similar vehicle. If the barrier is to be made operative then the vehicle is moved along a path on which the barrier is to be erected while the barrier is being payed out. This can be done in an effective and rapid manner.
The recovery of the barrier can however be tedious. The wire coils which make up the barrier have substantial resilience and carry barbs or spikes which are dangerous. Different techniques have been proposed to mechanise the recovery process.
For example South African patent No. 2006/08423 (which is related to WO2005/090716) describes a recovery device based on the use of a looped chain which moves continuously in one direction, drawing the barrier onto a boom. To the applicant's knowledge this recovery device is complex, and does not work satisfactorily.
An object of the present invention is to provide an improved apparatus for collecting a barrier.
SUMMARY OF THE INVENTION
The invention provides an apparatus for collecting a barrier which includes an elongate array of interconnected flexible coils, the apparatus including a support boom, a drive mechanism, a base member which is reciprocally movable by the drive mechanism, relative to the support boom and a catch which is mounted to the base member and which is movable to an inoperative position when the base member is moved in a first direction and which, when the base member is moved in a second direction which is opposite to the first direction, is movable to an operative position at which the catch is engageable with at least one coil, whereby part of the barrier is drawn, in an axially compressed state, onto the support boom.
The support boom may include a first end which is secured to an appropriate support structure and a second end which is positioned so that it extends into an interior of one or more adjacent coils. The second end may be curved downwardly to facilitate this process.
The drive mechanism may include a flexible drive element, such as a chain, which is in a closed loop. The base member, which is engaged with the drive mechanism, is preferably positioned to travel on a path which is parallel to the support boom. In a preferred form of the invention the base member is positioned to travel on a path which is directly below, and adjacent, the boom.
The catch may extend upwardly from the base member. The catch is preferably pivotally mounted to the base member. A biasing device such as a spring may be positioned to act between the base member and the catch and exert a biasing force on the catch which tends to move the catch to the operative position. A suitable stop may be provided on the base member which prevents movement of the catch beyond the operative position when the catch is moved away from the inoperative position.
The drive mechanism may include a prime mover such as an electric motor, a petrol or diesel engine, a hydraulic device or the like. The invention is not limited in this regard.
Preferably the apparatus includes a control unit which is operable by a technician and which allows the reciprocating movement of the base member to be controlled. The control which is exerted in this way may be in respect of at least one of the following: a speed of movement of the base member; a distance over which the base member is moved; a period for which the base member is moved; and a period for which the base member is stationary.
The invention further extends to a barrier recovery vehicle which includes a load area and apparatus of the aforementioned kind mounted to the load area.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a side view of apparatus according to the invention;
FIG. 2 is a view on an enlarged scale of a portion of the apparatus shown in FIG. 1 ;
FIG. 3 is a cross-sectional view taken on a line 3 - 3 in FIG. 2 of the apparatus of the invention;
FIG. 4 is a side view, similar to FIG. 1 , illustrating the apparatus in use; and
FIG. 5 shows a barrier with which the apparatus is usable.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 of the accompanying drawings illustrates, from one side, apparatus 10 , according to the invention, which is intended for use in collecting an elongate barrier 12 , a portion of which is schematically shown in FIG. 5 . This type of barrier is described for example in the specification of South African patent No. 98/10149.
FIG. 5 shows, only by way of example, a possible form of construction of the barrier which includes six coils 14 of razor wire arranged in a lowermost layer 14 A of three adjacent coils, a second layer 14 B of two coils positioned on the lowermost layer, and an uppermost coil 14 C arranged on the second layer so that, in cross-section, the coil configuration is generally triangular. Each coil, of razor wire or the like, comprises a plurality of helical windings. Adjacent coils are tied to each other in a manner which allows the windings to be compressed in an axial direction so that the barrier is arrangeable in a compact form which is suitable for storage or transport purposes but so that the compacted barrier can be expanded, in an axial direction, by displacing adjacent windings apart to a configuration of substantial elongate dimensions.
The barrier is readily deployed by moving a vehicle, from which the barrier, in a compressed state, is payed out, along a path on which the barrier is to be erected. As noted in the preamble to this specification, however, recovery of the barrier is not easily accomplished. The apparatus 10 is designed to allow the barrier to be recovered in a mechanised manner.
The apparatus 10 is mounted to a suitable recovery vehicle, not shown. The apparatus includes a pedestal 18 and an elongate support boom 20 which extends over a load area 22 of the vehicle. The boom, which is secured at a first end 24 to the pedestal, projects to a rear of the vehicle over the load area 22 , and curves downwardly over a region 26 to a lower second end 28 .
A major portion 30 of the support boom is elongate and generally horizontal.
A drive mechanism 32 , positioned below and parallel to the portion 30 , includes a support structure 34 with chain sprockets 36 and 38 respectively at opposed ends of the support structure. An endless chain 40 passes over the sprockets which are centrally positioned in the support structure—see FIG. 3 . A base member 44 , attached to the chain 40 , is positioned so that it can move horizontally together with the chain alongside the boom 20 .
The base member, on an upper surface, has a bracket 50 and a catch 52 is pivotally mounted to the bracket at a point 54 . A spring 56 acts between the base member and the catch and, in the illustrated example, tends to urge the catch in a direction 60 . A stop 62 , projecting upwardly from the bracket, prevents the catch 52 from moving beyond the illustrated vertical position ( FIG. 2 ) in the direction 60 .
The sprocket 36 is linked by a chain drive 70 to a prime mover 72 . The prime mover may be an electric motor which is battery driven, a petrol or diesel engine, a hydraulic system or the like. The invention is not limited in this regard. The direction of drive imparted by the prime mover to the chain 40 can be reversed using any appropriate technique known in the art. For example a small gearbox could be employed for this purpose, or the drive from the prime mover could be reversible. Preferably the drive process is controlled by means of a control unit 76 which allows the operation of the prime mover to be controlled, preferably wirelessly e.g. by means of a radio signal. Suitable control functions include the following: starting and stopping of the prime mover; reversal of the drive direction of the prime mover; varying the speed of movement of the prime mover; varying the period for which the prime mover is actuated; and varying the period for which the prime mover is inoperative.
FIG. 5 schematically illustrates a portion of the barrier 12 . Each coil 14 is made up of helically disposed windings 80 A, 80 B, . . . 80 N etc. These windings are usually made from tensile wire of substantial resilience.
In use of the apparatus the recovery vehicle is positioned so that the second end 28 of the support boom enters an interior of an elongate array of a number of the windings 80 , typically the windings in the uppermost coil 14 C adjacent a rear of the vehicle—see FIG. 4 . As the vehicle is moved towards the barrier there is a natural tendency for the windings to move up the curved region 26 onto the elongate horizontal portion 30 . A technician, not shown, then operates the prime mover. The base member is caused to move in a first direction 84 in a controlled manner alongside the boom towards the sprocket 38 . Windings 80 on the boom successively strike the catch 52 .
If a leading winding 80 A is anchored to the pedestal 18 then movement in the first direction 84 results in the catch 52 bending downwardly as each winding is traversed. Movement of the base member towards the sprocket 38 can be detected using a suitable limit switch 86 (shown in FIG. 2 ) so that, at this point, the drive from the prime mover is automatically stopped. The drive direction from the prime movement is then reversed. The spring-loaded catch 52 is then brought into contact with an adjacent winding 80 . As the catch is backed by the stop 62 , movement of the catch towards the pedestal causes the windings between the pedestal and the catch to be compressed in an axial direction. Some of the windings, trailing the catch, are thus drawn up onto the boom.
With each reciprocating stroke of the base member 44 additional windings are brought onto the boom by the catch. The length of the stroke of the base member is reduced as compressed windings accumulate on the boom adjacent the pedestal. The collection of windings should be carefully monitored by the technician so that corresponding movement of the base member, and thus of the catch, ensues. To prevent an overload of the prime mover when the base member is moved towards the pedestal, if the drive direction of the prime member is inadvertently not reversed, a suitable sensor can be employed to stop movement of the prime mover. For example, if the prime mover is electrically driven by means of a motor, a current sensor which is responsive to electrical current drawn by the motor, can be used to avoid an overload condition.
As the coil collection process continues it is desirable, from time to time, for the recovery vehicle to be moved towards an uncollected portion of the barrier still on the ground. This reduces the load imposed on the prime mover.
The invention makes it possible for a barrier comprising a number of elongate helical coils to be recovered in a mechanised manner.
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A barrier recovery device for receiving an elongate array of coils which includes a boom and a catch which is reciprocally movable along the boom to draw successive portions of the coils, in an axially compressed stated, onto the boom. The device can be mounted to a barrier recovery vehicle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. patent application Ser. No. 11/818,100, filed on Jun. 13, 2007 and entitled “EXTENSION TO UNIVERSAL SERIAL BUS CONNECOTR WITH IMPROVED CONTACT ARRANGEMENT”, and U.S. patent application Ser. No. 11/982,660, filed on Nov. 2, 2007 and entitled “EXTENSION TO ELECTRICAL CONNECTOR WITH IMPROVED CONTACT ARRANGEMENT AND METHOD OF ASSEMBLING THE SAME”, and U.S. patent application Ser. No. 11/985,676, filed on Nov. 16, 2007 and entitled “ELECTRICAL CONNECTOR WITH IMPROVED WIRE TERMINATION”, all of which have the same assignee as the present invention.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a cable assembly, more particularly to a cable assembly capable of transmitting optical signal.
[0004] 2. Description of Related Art
[0005] Recently, personal computers (PC) are used of a variety of techniques for providing input and output. Universal Serial Bus (USB) is a serial bus standard to the PC architecture with a focus on computer telephony interface, consumer and productivity applications. The design of USB is standardized by the USB Implementers Forum (USB-IF), an industry standard body incorporating leading companies from the computer and electronic industries. USB can connect peripherals such as mouse devices, keyboards, PDAs, gamepads and joysticks, scanners, digital cameras, printers, external storage, networking components, etc. For many devices such as scanners and digital cameras, USB has become the standard connection method.
[0006] USB supports three data rates: 1) A Low Speed rate of up to 1.5 Mbit/s (187.5 KB/s) that is mostly used for Human Interface Devices (HID) such as keyboards, mice, and joysticks; 2) A Full Speed rate of up to 12 Mbit/s (1.5 MB/s). Full Speed was the fastest rate before the USB 2.0 specification and many devices fall back to Full Speed. Full Speed devices divide the USB bandwidth between them in a first-come first-served basis and it is not uncommon to run out of bandwidth with several isochronous devices. All USB Hubs support Full Speed; 3) A Hi-Speed rate of up to 480 Mbit/s (60 MB/s). Though Hi-Speed devices are advertised as “up to 480 Mbit/s”, not all USB 2.0 devices are Hi-Speed. Hi-Speed devices typically only operate at half of the full theoretical (60 MB/s) data throughput rate. Most Hi-Speed USB devices typically operate at much slower speeds, often about 3 MB/s overall, sometimes up to 10-20 MB/s. A data transmission rate at 20 MB/s is sufficient for some but not all applications. However, under a circumstance transmitting an audio or video file, which is always up to hundreds MB, even to 1 or 2 GB, currently transmission rate of USB is not sufficient. As a consequence, faster serial-bus interfaces are being introduced to address different requirements. PCI Express, at 2.5 GB/s, and SATA, at 1.5 GB/s and 3.0 GB/s, are two examples of High-Speed serial bus interfaces.
[0007] From an electrical standpoint, the higher data transfer rates of the non-USB protocols discussed above are highly desirable for certain applications. However, these non-USB protocols are not used as broadly as USB protocols. Many portable devices are equipped with USB connectors other than these non-USB connectors. One important reason is that these non-USB connectors contain a greater number of signal pins than an existing USB connector and are physically larger as well. For example, while the PCI Express is useful for its higher possible data rates, a 26-pin connectors and wider card-like form factor limit the use of Express Cards. For another example, SATA uses two connectors, one 7-pin connector for signals and another 15-pin connector for power. In essence, SATA is more useful for internal storage expansion than for external peripherals.
[0008] The existing USB connectors have a small size but low transmission rate, while other non-USB connectors (PCI Express, SATA, et al) have a high transmission rate but large size. Neither of them is desirable to implement modern high-speed, miniaturized electronic devices and peripherals. To provide a kind of connector with a small size and a high transmission rate for portability and high data transmitting efficiency is much more desirable.
[0009] In recent years, more and more electronic devices are adopted for optical data transmission. It may be a good idea to design a connector which is capable of transmitting an electrical signal and an optical signal. Design concepts are already common for such a type of connector which is compatible of electrical and optical signal transmission. The connector includes metallic contacts assembled to an insulated housing and several optical lenses bundled together and mounted to the housing also. A kind of hybrid cable includes wires and optical fibers that are respectively attached to the metallic contacts and the optical lenses.
[0010] However, In the assembly process of a connector system that uses fiber optic cables, the fibers are stiff by nature. They are also very delicate and require protection if the fibers can be exposed. An example would be, but not limited to a USB connector type of application. The fibers when assembled within the plug housing, have the tendency to drift in unwanted locations due to their stiff nature.
BRIEF SUMMARY OF THE INVENTION
[0011] Accordingly, an object of the present invention is to provide a cable assembly has positioning means for securing fibers thereof.
[0012] In order to achieve the above-mentioned object, a cable assembly in accordance with present invention comprises an insulative housing having a base portion and a tongue portion extending forwardly from the base portion, said tongue portion defining a mounting cavity and at least two depressions, said two depressions located behind and located within the mounting cavity. An optical module is accommodated in the mounting cavity, said optical module having two lenses. Two fibers pass through the two depressions and coupled to the two lenses, respectively. Two cap members are accommodated in the two depressions to position the fibers therein.
[0013] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0015] FIG. 1 is an assembled, perspective view of a cable assembly in accordance with the first embodiment of the present invention;
[0016] FIG. 2 is an exploded, perspective view of FIG. 1 ;
[0017] FIG. 3 is similar to FIG. 2 , but viewed from another aspect;
[0018] FIG. 4 is a partially assembled view of the cable assembly;
[0019] FIG. 5 is other partially assembly view of the cable assembly;
[0020] FIG. 6 is a cross-section view of the cable assembly taken along line 6 - 6 ;
[0021] FIG. 7 is a partially assembled view of the cable assembly in accordance with the second embodiment of the present invention;
[0022] FIG. 8 is other partially assembly view of the cable assembly in accordance with the second embodiment; and
[0023] FIG. 9 is an enlarged view of a cap member of the cable assembly in accordance with the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details.
[0025] Reference will be made to the drawing figures to describe the present invention in detail, wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by same or similar reference numeral through the several views and same or similar terminology.
[0026] Referring to FIGS. 1-6 , a cable assembly 100 according to the first embodiment of the present invention is disclosed. The cable assembly 100 comprises an insulative housing 2 , a set of first contacts 3 , a set of second contacts 4 and a optical modules 5 supported by the insulative housing 2 , and a number of fibers 6 connected to the optical module 5 . The cable assembly 1 further comprises a cap member 7 and a metal shell 8 . Detail description of these elements and their relationship and other elements formed thereon will be detailed below.
[0027] The insulative housing 2 includes a base portion 21 and a tongue portion 22 extending forwardly from the base portion 21 . A cavity 211 is recessed upwardly from a bottom surface (not numbered) of the base portion 21 . A mounting cavity 221 is recessed downwardly from a top surface of the tongue portion 22 and the base portion 21 . A stopping member 2212 is formed in a front portion of the mounting cavity 221 . A positioning slot 222 is defined in a rear side of the mounting cavity 2212 and located within the mounting cavity 221 . A positioning post 2222 is arranged in the positioning slot 222 . Two depressions 224 are defined in the rear part of the tongue portion 22 and located within the mounting cavity 221 . The two depressions 224 are disposed opposite sides of the positioning slot 222 . A number of contact slots 212 are defined in an upper segment of a rear portion of the base portion 21 , and two fiber slots 214 are also defined in the upper segment of the rear portion of the base portion of the base portion 21 . The two fiber slots 214 are disposed between the two pair of adjacent fiber slots 214 , respectively.
[0028] The set of first contacts 3 has four contact members arranged in a row along the transversal direction. Each first contact 3 substantially includes a planar retention portion 32 supported by a bottom surface of the cavity 211 , a mating portion 34 raised upwardly and extending forwardly from the retention portion 32 and disposed in a depression 226 of the lower section of the front segment of the tongue portion 22 , and a tail portion 36 extending rearward from the retention portion 32 and accommodated in the terminal slots 212 .
[0029] The set of second contacts 4 has five contact members arranged in a row along the transversal direction and combined with an insulator 20 . The set of second contacts 4 are separated into two pair of signal contacts 40 for transmitting differential signals and a grounding contact 41 disposed between the two pair of signal contacts 40 . Each signal contact 4 includes a planar retention portion 42 received in corresponding groove 202 in the insulator 20 , a curved mating portion 44 extending forward from the retention portion 42 and disposed beyond a front surface of the insulator 20 , and a tail portion 46 extending rearward from the retention portion 42 and disposed behind a back surface of the insulator 20 . A spacer 204 is assembled to the insulator 20 , with a number of ribs 2042 thereof inserted into the grooves 202 to position the second contacts 4 in the insulator 20 .
[0030] The insulator 20 is mounted to the cavity 211 of the base portion 21 and press onto retention portions 32 of the first contacts 3 , with mating portions 44 of the second contacts 4 located behind the mating portions 34 of the first contacts 3 and above the up surface of the tongue portion 22 , the tail portions 46 of the second contacts 4 arranged on a bottom surface of the rear segment of the base portion 21 and disposed lower than the tail portions 36 of the first contacts 3 .
[0031] The optical module 5 includes four lens members 51 arranged in juxtaposed manner and enclosed by a holder member 52 and retained in the corresponding mounting cavity 221 . Furthermore, a coil spring member 9 is engaged with the holder member 52 , with a protrusion portion 54 of the holder member 52 extending into an interior of a front segment of the spring member 9 . A rear end of the spring member 9 is accommodated in the positioning slot 222 , and the positioning post 2222 projects into the rear end of the spring member 9 . Therefore, the optical module 5 is capable of moving backwardly and forwardly within the mounting cavity 221 .
[0032] Four fibers 6 are separated into two groups and pass through the fiber slots 214 , enter the two depressions 224 and are coupled to the four lens 51 , respectively. Each cap member 7 has a body portion 72 and two crush posts 72 formed on a bottom surface thereof. The cap member 7 is assembled to the tongue portion 22 , with body portion 72 accommodated in the corresponding depression 224 to cover and secure the fibers 6 in the depression 224 , and the crush posts 72 are inserted into holes 223 in the tongue portion 22 .
[0033] The metal shell 8 comprises a first shield part 81 and a second shield part 82 . The first shield part 81 includes a front tube-shaped mating frame 811 , a rear U-shaped body section 812 connected to a bottom side and lateral sides of the mating frame 811 . The mating frame 811 further has two windows 811 defined in a top side thereof. The second shield part 82 includes an inverted U-shaped body section 822 , and a cable holder member 823 attached to a top side of the body section 822 .
[0034] The insulative housing 2 is assembled to the first shield part 81 , with the tongue portion 22 enclosed in the mating frame 811 , the cap members 7 arranged underneath the windows 811 , and the base portion 21 is received in the body portion 812 . The second shield part 82 is assembled to the first shield part 81 , with body portions 822 , 812 combined together. The cable assembly may have a hybrid cable which includes fibers 6 for transmitting optical signals and copper wires (not shown) for transmitting electrical signals. The copper wires are terminated to the first contacts 3 and the second contacts 4 . The cable holder member 823 is crimped onto the cable to enhance mechanical interconnection.
[0035] Referring to FIGS. 7-9 , a cable assembly 100 ′ according to the second embodiment of the present invention is disclosed. The cable assembly 100 ′ in the second embodiment is similar with the cable assembly 100 in the first embodiment, except for a cap member 7 ′ and an insulative housing 2 ′. The cap member 7 ′ has two body portions 70 ′ arranged in parallel manner and connected together by a bridge portion 74 ′. Each body portion 70 ′ has two crush posts 72 ′ formed on a lateral side thereof. Furthermore, two crush posts 72 ′ are formed on the bridge portion 74 ′. The insulative housing 2 ′ has a depression 224 ′ which has similar configuration as the cap member 7 ′. The depression 224 ′ has two sub-depressions 2240 ′ and a channel 2242 ′ in communication with the two sub-depressions 2240 ′. Four holes 223 ′ are divided into two groups and defined in lateral sides of the tongue portion 22 ′ to receive the crush posts 72 ′ of the two body portions 70 ′. Other two holes 223 ′ are defined in the channel 2242 ′. The fibers 6 pass through the depression 224 ′ and connected to an optical module 5 . The cap member 7 ′ is accommodated in the depression 224 ′, with body portions 70 ′ located in the sub-depressions 2240 ′ respectively, the bridge portion 74 ′ received in the channel 2242 ′. Therefore, the fibers 6 are positioned in the depression 224 ′.
[0036] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the tongue portion is extended in its length or is arranged on a reverse side thereof opposite to the supporting side with other contacts but still holding the contacts with an arrangement indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A cable assembly ( 100 ) includes an insulative housing ( 2 ) having a base portion ( 21 ) and a tongue portion ( 22 ) extending forwardly from the base portion, said tongue portion defining a mounting cavity ( 221 ) and at least two depressions ( 224 ), said two depressions located behind and located within the mounting cavity. An optical module ( 5 ) is accommodated in the mounting cavity, said optical module having two lenses. Two fibers ( 6 ) pass through the two depressions and coupled to the two lenses, respectively. Two cap members ( 7 ) are accommodated in the two depressions to position the fibers therein.
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TECHNICAL FIELD
The present invention generally relates to three-phase voltage source inverters, and more particularly relates to the control of 4-leg three-phase voltage source inverters.
BACKGROUND
Three-phase voltage source inverters (VSI's) are generally used to convert DC power into three-phase AC power. Typically, the three-phase output voltages are sinusoidal waveforms spaced 120 degrees apart, to be compatible with a wide variety of applications requiring conventional AC power. In general, the output power frequencies commonly used are 50, 60, and 400 hertz, but other frequencies could be used as well. One current example of an inverter application is the electric or hybrid automobile, where a DC power source, such as a battery, fuel cell array, or other equivalent device, is converted into an AC power supply for various internal control functions, including the propulsion system.
The quality of an inverter is generally determined by its output voltage and frequency stability, and by the total harmonic distortion of its output waveforms. In addition, a high quality inverter should maintain its output stability in the presence of load current variations and load imbalances.
In the case of unbalanced loads, the 4-leg three-phase inverter topology is generally considered to offer superior performance than a 3-leg three-phase topology. That is, with an unbalanced load, the three-phase output currents from an inverter will generally not add up to zero, as they would in a 3-leg balanced load situation. Therefore, a fourth (neutral) leg is typically added to accommodate the imbalance in current flow caused by an unbalanced load. If a neutral is not used with an unbalanced load, voltage imbalances may occur at the load terminals, and the output power quality may be adversely affected.
The operational functions of a typical inverter are generally controlled by drive signals from an automatic controller. The controller and inverter are usually implemented as a closed loop control system, with the inverter output being sampled to provide regulating feedback signals to the controller. The feedback signals typically include samples of the output voltage and current signals, and can also include harmonics of the fundamental output frequency.
The ability of an inverter control system to compensate for undesirable harmonics is generally limited by the bandwidth of the system voltage control loop, which may not be adequate for compensating high frequency harmonic distortion. For example, in a typical cascaded voltage/current regulator configuration, the voltage loop bandwidth is generally limited to approximately 1/100 th of the sampling frequency. Due to technical factors, the sampling frequency is usually limited to a range of 5 to 20 kHz, thus limiting the voltage loop bandwidth to a range of 50 to 200 Hz. Therefore, harmonic compensation and transient response would be limited to frequencies within this range.
Moreover, the transient response characteristics of an inverter control system may also be limited by the overall execution time of the regulating loop software modules. That is, the larger the number of software modules, the greater the execution time, and the slower the transient response.
Accordingly, it is desirable to provide an inverter controller with a relatively high voltage control loop bandwidth, for improved harmonic compensation and transient response. In addition, it is desirable to provide an inverter controller with a minimal quantity of software modules, in order to speed up execution and reduce throughput time. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
BRIEF SUMMARY
According to various exemplary embodiments, methods and devices are provided for controlling a multi-phase stand-alone inverter. One method comprises the following steps:
a) converting the multi-phase inverter output from an AC domain to a DC domain equivalent, where the DC equivalent includes feedback voltage elements and associated feedback current elements, each voltage element and associated current element corresponding to one phase of the multi-phase output; b) comparing each of the feedback voltage elements to a corresponding reference voltage to create corresponding difference voltage signals; c) processing the difference voltage signals to create voltage regulating signals, where each of the voltage regulating signals includes a fundamental compensating component combined with an imbalance compensating component; d) limiting the voltage regulating signals with a current limiting factor derived from the feedback current elements; e) converting the voltage regulating signals to AC domain equivalents; f) processing the AC domain equivalents to produce a set of control inputs to the inverter; g) providing the set of control inputs to the inverter to enable compensating regulation of the fundamental and imbalance characteristics of the multi-phase output of the inverter.
An exemplary embodiment of a device for controlling a multi-phase stand-alone inverter includes:
a converter configured to transform the alternating current multi-phase output to a direct current equivalent, where the direct current equivalent includes feedback voltage elements and associated feedback current elements, each voltage element and its associated current element corresponding to one phase of the multi-phase output; a set of regulators, each regulator corresponding to a respective feedback voltage element, with each regulator configured to compare its respective feedback voltage element to a corresponding reference voltage to create a difference voltage signal, and to process the difference voltage signal into a voltage regulating signal, including a fundamental compensating component and an imbalance compensating component; a set of limiters, each limiter corresponding to one of the voltage regulating signals and configured to limit its respective voltage regulating signal with a current limiting factor derived from the feedback current elements; an inverse converter configured to inverse transform the voltage regulating signals into alternating current equivalents; an inverter driver configured to process the alternating current equivalents to produce control inputs to the inverter that enable compensating regulation of the fundamental and imbalance characteristics of the multi-phase output.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
FIG. 1 is a block diagram of an exemplary four-leg three-phase inverter system;
FIG. 2 is a simplified block diagram of an exemplary inverter controller; and
FIG. 3 is a detailed block diagram of an exemplary embodiment of an inverter controller.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
Various embodiments of the present invention pertain to the area of voltage source inverters operating in a stand-alone mode. Generally, this type of inverter is used to convert DC power available at a selected voltage into AC power with fixed voltage and frequency. Ideally, the output voltage and frequency stability of an inverter should be independent of load variations and imbalances. To provide this type of stabilization, an inverter controller may be used in a closed loop feedback configuration to provide regulating and imbalance compensating signals to the inverter. The inverter controller may be implemented in hardware or software, or any combination of the two.
As previously noted in the Background section, the four-leg inverter topology is generally used for quality AC power generation into a three-phase unbalanced load application. The fourth leg provides a return path for the neutral imbalance current of a three-phase load.
A three-leg inverter configuration typically connects the load neutral to the mid-point of two series-connected capacitors across the DC voltage source. In this configuration, the AC output voltage would be approximately 0.5Vdc, whereas the four-leg configuration provides an AC output voltage of approximately 0.578Vdc. A further advantage of the four-leg configuration is that a smaller, single capacitor can be used instead of the two required for the three-leg approach.
According to an exemplary embodiment of a four-leg three-phase inverter system 100 , shown in FIG. 1 , a DC voltage source 102 supplies a selected level of voltage (Vdc) to an inverter/filter 104 connected to a three-phase four-wire load 106 . Inverter/filter 104 typically comprises an input (link) capacitor C L connected across source 102 , and in parallel with four sets of switching circuits 103 , which generate a three-phase output signal via L-C filter 105 to the load 106 . Inductor L n represents the inductance of the neutral line.
An inverter controller 108 is typically configured to receive voltage and frequency command signals from a control unit (not shown in FIG. 1 ), and to also receive feedback signals from the input Vdc and from the outputs of inverter/filter 104 at the inputs to load 106 . Inverter controller 108 processes the command and feedback signals to create output drive signals for the inverter/filter 104 switching circuits 103 . The inverter controller 108 output drive signals may include voltage and current regulating elements as well as load imbalance compensating elements.
FIG. 2 depicts a simplified block diagram of inverter controller 108 within the closed loop four-leg three-phase inverter system 100 . In this embodiment, an external control unit 110 typically provides reference signals, such as voltage, current, frequency, etc., to inverter controller 108 to establish the desired output voltage and frequency values of inverter/filter 104 . In an alternate embodiment, control unit 110 could be integrated within inverter controller 108 .
Voltage regulator blocks 112 , 114 , 116 receive voltage reference signals from control unit 110 while a current limiting block 126 receives a current reference signal from control unit 110 . Samples of the voltage and current outputs from L-C filter 105 are transformed from the AC domain to the DC domain in block 124 , which receives a frequency reference signal from control unit 110 . Voltage feedback signals from block 124 are fed to corresponding voltage regulator blocks 112 , 114 , 116 , and current feedback signals from block 124 are fed to current limiting block 126 . A current limiting signal from block 126 is applied to voltage regulator blocks 112 , 114 , 116 .
Voltage regulating blocks 112 , 114 , 116 generate regulating signal outputs that are limited by the output of current limiting block 126 . The regulating signal outputs are inverse transformed from the DC domain to the AC domain in block 120 , which receives a frequency reference signal from control unit 110 . The transformed regulating signals are then processed by block 122 into driving signals for the inverter 104 switching circuits 103 . A more detailed description of the operation of inverter controller 108 is given below in conjunction with FIG. 3 .
An exemplary embodiment of an inverter controller 108 for a four-leg three-phase inverter/filter 104 is shown in a more detailed block diagram form in FIG. 3 . In this embodiment, the block functions within inverter controller 108 are implemented in software modules to constitute a control algorithm for inverter/filter 104 . This approach utilizes the Park transformation, as is known in the electrical machine art (see “Analysis of Electric Machinery” by Krause, Paul C., Wasynczuk, Oleg and Sudhoff, Scott D.; IEEE Press 1995, Institute of Electrical and Electronics Engineers, Inc.), to convert the sampled output signals from an AC domain to a DC domain in order to simplify the mathematical processes implemented within inverter controller 108 . An inverse Park transformation is then used to convert the processed DC domain signals back to the AC domain for the control inputs to the inverter switching circuits 103 . Other techniques for converting from the AC domain to the DC domain could be used in a wide array of equivalent embodiments.
The basic concept of the Park transformation is known as the synchronous reference frame approach. That is, a rotating reference frame is utilized in order to make the fundamental frequency quantities appear as DC values. A common convention is to label the AC domain (stationary reference frame) quantities, such as phase voltages and currents, as “abc”, and to label the corresponding Park-transformed DC domain (synchronous reference frame) quantities as “dq0”. This labeling convention will be followed throughout the following discussion.
Reference values for voltage, current and frequency are generally determined within a control unit 110 to establish desired values of inverter output voltage and frequency within a maximum current limit. The voltage references are shown in FIG. 3 as V* d , V* q , V* 0 , which are typically calculated Park transformations of predetermined reference three-phase voltage values. The maximum current limit value is shown in FIG. 3 as I inv — max , and the reference frequency is represented as ω*.
The inverter/filter 104 three-phase output voltages and currents may be measured by any conventional method to create feedback signals to inverter controller 108 . The voltage feedback signals are typically measured between phase and neutral, and are designated herein as V an , V bn , V cn . The current feedback signals can be measured by line sensors on each phase, and are designated herein as I a , I b , I c .
Voltage feedback signals V an , V bn , V cn are converted from AC domain to DC domain equivalents via the Park transformation in block 124 . The reference angle used for this transformation is designated θ*, and is generated by an integrator block 23 from the reference signal ω*. The transformed voltage feedback signals are designated V d , V q , V 0 and are fed back with changed sign to adders 1120 , 1140 and 1160 , respectively. The reference voltage signals V* d , V* q , V* 0 are also inputted to adders 1120 , 1140 and 1160 , respectively, to generate voltage error signals (V* d −V d , V* q −V q , V* 0 −V 0 ) at the outputs of the respective adders 1120 , 1140 , 1160 .
The voltage error signals V* d −V d , V* q −V q , V* 0 −V 0 are routed through proportional-integral (PI) controller blocks 1122 , 1142 , and 1162 , respectively, for amplifying and smoothing. At the same time, voltage error signals V* d −V d , V* q −V q , V* 0 −V 0 are also routed through band pass filter blocks 1128 , 1148 , and 1168 , respectively.
Referring now to the d-axis voltage regulator ( 112 ) in this embodiment, block 1128 is configured as a second order band pass filter with an adjustable gain. The center frequency of filter 1128 is set at twice the reference frequency ω*, in order to provide a high gain for the d-axis voltage controller at this particular frequency. This is intended to compensate for an unbalanced inverter output voltage condition, where a voltage component at twice the fundamental frequency appears in the voltage feedback signal. By placing band pass filter 1128 in a parallel path within the d-axis voltage controller 112 , the loop gain can be increased at 2*ω* without affecting the phase and gain margin of the system.
The output signals from blocks 1122 and 1128 are combined in adder 1124 , along with a quantity −ω*LI q . This latter quantity is a feed-forward term, which may be obtained from control unit 110 by transforming the steady-state equations of the filter 105 from the stationary reference frame to the synchronous reference frame. The feed-forward term −ω*LI q is used in this embodiment to improve the transient response of the d-axis voltage regulator 112 , and to reduce the cross-channel coupling between the d-axis and q-axis controllers ( 112 and 114 ). For the q-axis controller 114 , the corresponding feed-forward term is ω*LI d .
The q-axis voltage regulator 114 operates in essentially the same manner as the d-axis voltage regulator 112 , except for the feed-forward term, as noted above.
The 0 -axis voltage regulator 116 differs from the d-axis and q-axis regulators ( 112 , 114 ) in that its associated band pass filter 1168 is tuned to ω*, rather than 2*ω*. This is due to the fact that an unbalanced output voltage condition will generally produce a fundamental frequency component on the 0 -axis feedback signal. Also, there is generally no need for a feed-forward signal in the 0 -axis channel.
The outputs of adders 1124 , 1144 and 1164 are routed through limiter blocks 1126 , 1146 , and 1166 , respectively. Limiter blocks 1126 , 1146 , 1166 also receive a common input signal from current limiter 126 , as will be described below. The limited output signals of blocks 1126 , 1146 , 1166 are then processed in block 120 from DC domain (dq 0 ) to equivalent AC domain (abc) by means of an inverse Park transformation, using the reference angle θ*.
The regulating output signals from block 120 are designated V a , V b , V c , and are normalized in block 122 by a multiplication factor (√3/V dc ), which is the inverse of the maximum achievable inverter phase output voltage for a given DC input voltage (V dc ). The normalized regulating voltages may be used to control the pulse train duty cycles of a conventional Pulse Width Modulator (PWM) within block 122 , or through any other technique. The duty cycle modulated pulse trains, designated as d abcn , are configured as the drive signals for the switching circuits 103 in inverter/filter 104 . The switching devices in switching circuits 103 , as depicted in FIG. 1 , may be MOSFET's, IGBT's (Insulated Gate Bipolar Transistor), or any type of switching device with appropriate speed and power capabilities.
Referring now to the operation of current limiting block 126 , current feedback signals I a , I b , I c are converted from AC domain to DC domain equivalents via the Park transformation in block 124 . The transformed current feedback signals are designated I d , I q , I 0 and are fed into a summing block 1260 within current limiting block 126 . The amplitude of inverter/filter 104 output current I inv is calculated in summing block 1260 , based on the square root of the sum of the squares of the current feedback signals I d , I q , I 0 . This calculated value (I inv ) is combined with the maximum current limit value I inv — max in adder 1262 to form a difference signal (I inv — max −I inv ). This difference signal is then amplified and smoothed in a PI block 1264 , so that the dynamics of the regulator are adequate for a fast reacting over-current protection. Block 1266 processes the output of block 1264 into a limiting factor, such as in the range of 0 to 1, where 1 corresponds to the maximum current limit. This limiting factor is then applied to the three limiting blocks 1126 , 1146 , 1166 as a multiplier, to add over-current protection to the voltage limiting function of blocks 1126 , 1146 , 1166 .
It should be noted that the PI controllers ( 1122 , 1142 , 1162 , 1264 ) in FIG. 3 each receive a feedback signal from their respective limiting modules ( 1126 , 1146 , 1166 , 1266 ). This feedback scheme, known in the art as “integrator anti-wind-up”, improves the transient behavior of the PI controllers.
The previously described drive signals from controller 108 to the switching circuits 103 provide the desired regulating control for the multi-phase output of inverter/filter 104 . As such, controller 108 and inverter/filter 104 constitute a closed-loop feedback system for maintaining the stability and quality of the inverter/filter output.
In summary, the architecture of the inverter control algorithm, as disclosed in the exemplary embodiment of FIG. 3 , provides a combination of voltage regulation, imbalance compensation, and over-current protection, with fast transient response, short execution time, and high harmonic suppression. Verification tests have demonstrated a voltage loop bandwidth capability of approximately 600 Hz for a sampling frequency of 12 kHz. Tests have also shown that voltage regulation (approximately 1%) and total harmonic distortion (approximately 2%) are essentially the same for a 100% unbalanced load operation as they are for a 100% balanced load operation.
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof.
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Methods and apparatus are provided for controlling a stand-alone four-leg three-phase inverter. The inverter three-phase output is converted from AC domain elements to corresponding DC domain elements. The DC domain elements are processed into combined regulating and imbalance compensating signals, including over-current limiting. The compensating signals are restored to corresponding AC domain signals, and are processed into control inputs for the inverter, in order to stabilize the inverter output when connected to an unbalanced load. The inverter controller can be implemented entirely in software as a control algorithm.
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[0001] This non-provisional patent application is filed in reference to its predecessor provisional application filed on Feb. 25, 2013 and assigned Ser. No. 61/650,925.
FIELD OF THE INVENTION
[0002] The present invention relates generally to games of physical skill, and more specifically to a game played by children of a relatively tender age using playing pieces within a circumscribed area, such as, in its simplest form, a circle. The present invention further involves the manipulation of the playing pieces, specifically marbles, with each player using a special tool, developed for use with the game.
BACKGROUND OF THE INVENTION
[0003] In the past, the relatively simple children's game of marbles was played within a circle or a generally circular area scribed on the ground. The winner was the player who collected the most marbles from the circle. Typically, when the game was played on a well-worn playground during school recesses, the circle was drawn on the ground and the players effectively formed a larger circle around the drawn playing area and enjoyed their play. Now, even most schoolyards are covered with grass and are well manicured. Certainly, this is also the case of most home yards, and areas safe for children to play where a circle can be drawn in the dirt are harder to find. In particular, marble games that can be played inside are desirable as well.
[0004] Accordingly, the need arises for a game apparatus for teaching manual dexterity, eye-hand coordination, and related skills to young children that have the convenience of making the game playable indoors and outside by providing the area for play without regard to the character of the supporting surface, except that it is relatively flat. It is also desirable to provide for the indirect handling of the game pieces to add further challenge to the game and improve eye-hand coordination.
DESCRIPTION OF THE PRIOR ART
[0005] The prior art of games, generally, includes many games for play by children and adults that use marbles or other game pieces but still does not achieve the goals and benefits of the instantly claimed invention, particularly as regards ease of play by children of a tender age. These prior art disclosures include:
[0006] U.S. Pat. No. 5,458,342 issued to Leonel G. Hernandez on Oct. 17, 1995, discloses a game for teaching manual dexterity for a plurality of players, comprising a plurality of groups of individual playing pieces, with each of said playing pieces having a top surface and an opposite bottom surface of different configuration and with each of said groups having means providing for differentiation from other said groups, a common playing arena, providing for placement of said groups of individual playing pieces therein, a plurality of receptacles providing for the containment of said individual playing pieces when said individual playing pieces are removed from said common playing area, with each of said receptacles corresponding to one of said groups of individual playing pieces and including means providing for identification with said corresponding one of said groups and for differentiation, from other said receptacles, a plurality of tongs providing for the grasping of said individual playing pieces, with each of said tongs corresponding to one of said groups of individual playing pieces and including means providing for identification with said corresponding one of said groups and for differentiation from other said tongs, and timer means providing for the determination of an interval of time for a turn of play, whereby each of said groups of playing pieces, said receptacles, and said tongs are assigned to different players, said playing pieces are randomly placed inverted within said common playing arena with said bottom surface of each of said playing pieces facing upward, and each of the players simultaneously first attempts to turn upright said playing pieces assigned to that player by means of said tongs assigned to that player and then attempts to remove said playing pieces assigned to that player to said receptacle assigned to that player by means of said tongs assigned to that player, with play being limited by said timer means;
[0007] U.S. Pat. No. 5,240,260 issued to Ned Strong in on Aug. 31, 1993, discloses a Toy Game Apparatus comprising a generally vertically disposed set of playing piece receptacles on a rotatable curved frame. The frame includes means to cause the rotation thereof when triggered by a sound, thus causing the receptacles to move and making it more difficult for a player to place any playing pieces in the receptacles. No timer means is disclosed. The object is to place playing pieces on specific points of the intermittently moving apparatus by using a pair of tongs, rather than to remove playing pieces from a playing surface or arena. The relatively complex electronic apparatus providing for movement of the vertical array of playing piece receptacles, is unlike the relatively simple configuration of the present game apparatus with its flat playing area;
[0008] U.S. Pat. No. 5,040,789 issued to Jimmy R. House on Aug. 20, 1991, discloses a Game Apparatus And Method For Playing A Game comprising a bladed game piece and a slotted receptacle therefor. The object of the game is to use a pair of sticks to pick up the playing piece and deposit it on the slotted receptacle, with the receptacle slots engaging the blades. A timer is used to time the duration of each move. No common playing surface or arena is provided, and only a single playing piece is disclosed;
[0009] British Patent No. 1,533,473 to Marvin Glass And Associates and published on Nov. 22, 1978, discloses a Playing Object Retrieval Game in which a plurality of playing pieces resembling pickles are placed in a jar. The object is to remove the playing pieces using a tool resembling a fork with bent tines;
[0010] British Patent No. 1,517,498 to Agatsuma Ltd. and published on Jul. 12, 1978, discloses an Apparatus For Playing A Game comprising a game board having a plurality of remotely actuated grasping slides thereon. The slides are manipulated in an attempt to grasp balls in the center of the board and move them to individual player storage areas;
[0011] U.S. Pat. No. 3,954,262 issued to Leonard J. Weber on May 4, 1976, discloses a Game Device wherein playing pieces are removed from a central area and placed in specific playing positions around the periphery of a circular board as rapidly as possible. The duration of time allowed is dependent upon the spinning of a top. When the top falls, the bottom of the central area is opened electronically to allow any remaining playing pieces to fall through, whereby access to them is precluded. Another conventional clock is also used to time each turn;
[0012] U.S. Pat. No. 3,721,440 issued to Howard M. Burns on Mar. 20, 1973, discloses a Manual Dexterity Game in which a pickup device is slidingly secured on a string suspended between two remotely operated arms. Each of the arms is manipulated by one hand of the player. The object is to remotely move a game piece from one point to another on the playing surface; and
[0013] U.S. Pat. No. 3,717,341 issued to Colecta E. Blanton, Jr. on Feb. 20, 1973, discloses a Board Game Apparatus in which a pair of chopsticks is used to handle a plurality of rounded, smooth counters in moving the counters from one point to another on the game board. The present game board or arena includes an upturned periphery for containment of the playing pieces and is devoid of specific points within the arena.
[0014] None of the above noted patents, taken individually or in combination, are seen either to disclose or make obvious the specific arrangement of concepts disclosed by the present invention.
SUMMARY OF THE INVENTION
[0015] By the present invention, an improved game for teaching manual dexterity using tools appropriate for very small children to hold and operate is disclosed. Moreover, an improved simplified game for teaching rule-following for very young children to provide a transition to more difficult and more complicated games as they age is disclosed herein.
[0016] Accordingly, one of the objects of the present invention is to provide an improved game for teaching manual dexterity and eye-hand coordination that includes game apparatus comprising a common playing area or arena for the individual playing pieces, and a plurality of individual playing pieces.
[0017] Another of the objects of the present invention is to provide an improved game for teaching manual dexterity and eye-hand coordination that includes means for the indirect handling of playing pieces, comprising tools for each player with handles easily held by very small hands. The tool basically comprises a tube of indeterminate length and of a diameter large enough to admit the game marbles assigned each individual player and a neutral marble, distinguishable from all players' marbles within the tube. One end of the tube is designed to “pick up” said marbles when the player places that end of the tube over the marble. The opposite end of the tube is attached to a rounded, globular handle designed for ease of grasp and control by small hands. The shape of the handle is not critical to the invention, as long as it is “designed for ease of grasp and control by small hands.” The distance between the end of the tube for capturing the marbles and the handle for manipulation of the tube is designed such that the indirect nature of manipulation between the point of capture and the player's hands is to require skill in its operation and to develop eye-hand coordination in the young player.
[0018] Yet another object of the present invention is to provide an improved game for teaching manual dexterity which game is particularly suited to play by small children, and which game components are devoid of sharp edges and other hazards to small children.
[0019] A final object of the present invention is to provide an improved game for teaching manual dexterity for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purpose.
[0020] With these and other objects in view which will more readily appear as the nature of the invention is more fully disclosed as comprising of the novel combination and arrangement of parts hereinafter more fully described, illustrated and claimed with reference being made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a common arena 10 , defined by an inside wall 11 of one example of a construction for playing the present game, showing a view from the top looking into the circle for retaining the marbles for which each of the players compete, with the area 12 outside the circle but within the outer square forming the continuous wall 10 a of the circle.
[0022] FIG. 2 is a perspective view of an exterior side wall 10 a of the outer square and inside wall 11 showing the three dimensional character of the circle formed thereby.
[0023] FIG. 3 is a perspective view of another side 10 a portion of the outer square and its corresponding inside wall 11 showing the three dimensional character of the circle formed thereby.
[0024] FIG. 4 is a perspective view of the grabbing tool 4 in an upright position used for the manipulation of the individual playing pieces of the game. The grabbing tool is divided generally into a tubular bottom portion 4 a for capture and receipt of a marble game piece and a rounded globular top portion 4 b , which acts as a handle for the tool and which is attached to the bottom tubular portion 4 a in a manner for ease of removal for collecting the marbles from tube 4 a for re-use.
[0025] FIG. 5 is a perspective view of the tool of FIG. 4 turned 90 degrees to the right.
[0026] FIG. 6 is a cross-sectional view of the tool of FIGS. 4 and 5 taken at the center (widest) point along the top portion thereof. The larger, outside circle represents the circumference 6 a of the globular portion 4 b of the Grabber tool 4 . The broken circle 6 b within the larger circle 6 a represents the bottom opening of the tube portion of the tool; the smaller broken circle 6 c within circle 6 b shows the opening in the bottom of the tube formed to be somewhat smaller than the diameter of the marbles used in the invention game; and the broken straight lines 6 d within the larger broken circle show the creation of divisions 6 e of the bottom of the tube which act to first surround a marble, then each division 6 e moves past the center portion (i.e., widest circumference) of the marble to a position underneath the marble, which marble is then taken into the tool. This capture means is facilitated by using a flexible material circumscribed by dotted lines 6 b and 6 c.
[0027] FIG. 7 is a two dimensional depiction of a player's marble 7 , sometimes designated as a “Grab” marble, a predetermined number of which the player must collect before being eligible to grab the single “neutral” marble 8 to become the game winner.
[0028] FIG. 8 is a two dimensional depiction of the single neutral 8 marble, sometimes designated as a “Grab It” marble, used in the game.
[0029] FIG. 9 shows a top 13 covering the area 10 . In this depiction, the top 13 is shown recessed within the space between inside wall 11 and outside wall 10 a.
[0030] FIG. 10 shows top 13 as a top or cover for the open area 10 and resting between inside wall 11 and outside wall 10 a by having a diameter size between the diameter sizes of walls 11 and 10 a . Options for ease of removal of top 13 include a finger hole within the diameter of top 13 or a handle of some shape or form placed on the upper side of top 13 within said diameter.
[0031] FIG. 11 shows a side view of a possible separate container 14 and lid 15 therefor for storing the playing marbles for an individual player. In such a preferred embodiment, there is provided a container 14 for each set of like-colored marbles.
[0032] FIG. 12 shows a side view of a larger container 16 for holding the total of containers 14 , including multiple neutral colored marbles used for determining the game winner, and the grabber tools. Lid (or top) 17 is also shown for enclosing the content within container 16 .
[0033] FIG. 13 shows closed (“lidded”) container 16 from a perspective looking down from above the top of said container and lid 17 .
[0034] The described FIGS. 1-13 show similar reference characters to denote corresponding features consistently throughout the several figures of the attached drawings and in the following Detailed Description.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] The present invention relates to a game for teaching manual dexterity, and game apparatus therefor. FIG. 1 of the drawings discloses an arena 10 which is used in playing the game. A single arena 10 is provided, with its use common to all players of the game. The arena 10 is defined by a generally circular periphery wall 11 within which each player's marbles 7 (often designated as “Grab” marbles) and a single neutral marble 8 (often designated as the “Grab It” marble) are placed before the game begins. The concept of the arena is merely a defined space within which each player's Grab marbles and the single Grab It marble are to be confined during the process of their collection by the players as the game progresses. This could be as simple as drawing a rough circle in the sand or dirt. A generally circular shape is preferred only to provide each player the same opportunity for success in the game. If there are four players, the arena shape could just as easily be drawn as a square with each player occupying a separate side. The most preferred embodiment is three dimensional and circular as depicted as shown in FIG. 1 as an open area, or arena, 10 . The walls 11 of the arena provided by its third dimension assist in keeping the Grab marbles 7 and the Grab It marble 8 within the arena during the melee of the players simultaneously using their tools 4 to collect the marbles 7 and 8 (often designated as “Grabber tools”) required to win the game under way. The wall 11 may vary in thickness, as shown in FIG. 1 , or it may be of a uniformly continuous width producing inner and outer concentric circles (or other geometric shapes). The Grabber tool 4 as shown in FIGS. 4-6 is essentially a collection tube 4 a with a marble entry port 6 c at one end of the tube and a rounded, globular handle 4 b at its other end. The handle shown in FIGS. 4 and 5 represent a preferred embodiment. Such handle function could easily be of a different configuration and remain within the conception of the instant invention. For example, it could take the shape of a simple “T” permitting easy grasp and control by small hands. Also, other handle designs (such as a flattened oval permitting the fingers of a small hand to be inserted for grasping the Grabber tool 4 ) could be used without diverting from the game conceptualized and herein disclosed for use in the instant invention. The disclosed invention anticipates any equivalent handle shape that permits grasping and controlling the tool for capturing the designated playing pieces. The particular preferred embodiment as shown in FIGS. 4 and 5 have the attributes both of ease of control and no sharp edges.
[0036] As a single game does not require much passage of time, there is generally prior agreement among the players as to the number of games to be played to determine an overall winner. The arena 10 is of sufficient size to provide for the initial placement and containment of an equal number of Grab marbles 7 for each of a plurality of players therein and a single Grab It marble 8 . The object of the game is for each player to remove his/her (and only his/her) Grab marbles 7 from the common arena 10 as rapidly as possible. Accomplishment of this task permits a player then to capture a single neutral marble 8 (different from the other marbles) to declare himself/herself as winner of the game.
[0037] One means for permitting the Grab marbles 7 and Grab It marble 8 to enter into the tube 4 a when it is placed over said marble is to provide placement at the end of tube 4 a a washer-like semi-closure made of a rigid or semi-rigid material, such as a plastic material of suitable plasticity or a rubber material of suitable flexibility. Such plastic or rubber material may lie in a plane perpendicular to a plane along the length of the tube 4 a and partially cover one end of the tube 4 b around said end's circumference 6 b and leaving an opening 6 c in the center, which opening has a diameter some degree smaller than the diameter of the marble to be captured.
[0038] Due to vigorous actions taken be a player to rapidly capture the game marbles ahead of other players in order to win the game, the tube 4 itself should be made of a material of some rigidity and durability. While this can be a plastic material, if the material used for the marble pick-up means shown in FIG. 6 partially covering the end of the tube 4 a must be flexible enough to move to a degree to permit marble pick-up. This could be accomplished by dividing (by cutting or other means) into multiple sections 6 e whereby a marble may be “grabbed” by placing the partially covered end of the Grabber tool 4 over the marble and, by pushing the tube down the multiple sections of plastic material will bend to slide by the circumference of the marble and the energy being stored in the elastic material will produce a spring action of each of said multiple sections upon completely passing the marble and will push the marble up into the body of the tube. Also, various alternative means for permitting capture of the marble game pieces are envisioned and may be employed. One such alternative means includes attaching to the end of the Grabber tool tube for marble capture a rubber (or “rubberized”) washer, the outside diameter of which is generally the diameter of the capture tube of the Grabber tool 4 and the inside diameter of the washer is just smaller than the diameter of the marble game pieces to be captured; whereas the flexible nature of the washer material permits expansion of the inside washer diameter to accommodate passage there through of the marble but return to its normal diameter after said passage prevents the marble game piece from exiting the capture tube via the same route.
[0039] At the other end of the tube portion of the Grabber tool 4 is located a rounded, globular handle 4 b . The tube 4 a should be of sufficient length to hold the number of Grab marbles 7 and the single Grab It marble 8 used in the game, as such storage capacity within said tube 4 b will determine the maximum number of Grab marbles 7 (plus a single Grab It marble) that can be collected. Clearly, there is a relationship between the tube 4 a size (length and diameter) and marble size, which relationship allows manipulation to determine the optimal number of marbles in a game. Also, entering into this relationship is the age/size of the potential players. The size of the grabber tools must be appropriate to an age range, which also permits manipulation of the number of marbles that may be employed, with the greater the number, the greater the challenge and range of skill development. So, the game itself may be produced for various aged players from toddlers to adults.
[0040] Ideally, this handle 4 b is designed to be easily removed from the tube 4 a for recovering the marbles to play the next game. Such tube-handle assembly may be accomplished in any prudent fashion. Optional connection/release means may include, but no be limited to, (1) a push-on/pull-off operation, relying on adequate pressure and friction to maintain the connection between pushing on and pulling off, or (2) the handle end of tube 4 a and a portion within the handle 4 b may be threaded in male-female fashion to permit screwing/unscrewing the tube 4 a and handle 4 b between capturing and retrieving the Grab marbles 7 and/or Grab It marble 8 . Certainly, other means of attachment may be employed and are considered within the scope of disclosure herein. The location of the handle 4 b somewhat distant from the capture end of tool 4 a allows easy grasp and manipulation by a player with small hands. It also serves to allow the player to develop both manual dexterity and eye-hand coordination at a very young age, or improvement of such coordination at any age.
[0041] The Grab marbles 7 are provided in multiples of different groups, each group being differently configured in some way in order to distinguish between each group. In a preferred embodiment, each group is of a different color (e.g., green, yellow, orange, purple, etc.; other colors may be used as desired) to enable small children to recognize playing pieces (marbles) belonging to a given group. Alternatively, marble identifiers could be marbles with a different letter surrounding their surface. This would reinforce learning letters by very young players. Or, the marbles may be stripped versus checkered versus covered with squares versus covered with triangles versus covered with hexagons, etc. The point is that the particular chosen marble group identifier is not determinative on the scope of the instant invention, as the fact of distinguishing between/among them is an element of the invention's conception and reduction to practice, and any equivalent means of accomplishing differentiation between or among the groups of Grab marbles 7 is anticipated within the scope of the invention. The same concept applies to the Grabber tools 4 . For example, when the different multiple groups' distinguishing identifier is color, each Grabber tool 4 is of the same color as each multiple of different colored groups of Grab marbles 7 . The use of different colors for each group is particularly advantageous for smaller children who have not yet developed fine perception skills to distinguish more subtle differences, and who can easily associate the color of their Grabber tool 4 with the color of their assigned multiples of Grab marbles 7 . The advantage of other distinguishing identifiers as listed above herein permits and or reinforces learning the alphabet, or geometric shapes or whatever category of which the distinguishing identifier may qualify. Only a single neutral (dissimilar to the Grab marbles 7 ) Grab It 8 marble is required to play the game, although it may be prudent to have one or more extra Grab It 8 marbles available to replace one that may become lost. The larger number of same color Grab marbles 7 each player will have to capture to be eligible to capture the single neutral Grab It 8 marble, the greater the manual dexterity, eye-hand coordination, and recognition skills that will be required to win the game. This permits adjustment of the number of Grab marbles 7 to be required to capture before grabbing the Grab It marble 8 . So, the game can be played with an appropriate number of Grab marbles 7 for the age or skill level of the players. Also, the game may be adjusted for the younger player who either ages and/or increases skill and abilities in regularly playing the game. In this way the game doesn't become boring, and the game can grow along with the child player. An appropriate number of marbles for players of a tender age, e.g., approximately three years and just older, may be three or four Grab marbles 7 to limit frustration while developing their skills at manipulating the Grabber tools 4 to collect the Grab marbles and the Grab It marble.
[0042] The game is played is by placing an equal number of the individual playing pieces, such as Grab marbles 7 , for each player within the arena 10 , along with a single Grab It marble 8 . All of the players simultaneously attempt to be first to capture all their like-identified Grab marbles 7 , using their like-colored Grabber tool 4 , and then to capture the lone, differently identified Grab It marble 8 , also using their Grabber tool 4 , which corresponds to the identifier for their respective Grab marbles 7 . The object is to be the first player to complete the two above steps. The first player to accomplish both tasks must also yell “Grab It!” after grabbing the Grab It marble 8 to be the winner. In the possible instance where one player may capture another player's Grab marble 7 , the game is immediately stopped by any player; the erroneously captured marble is credited as captured by the player whose marble it is; and the player who erroneously captured the marble is removed from completion of that specific game, which game then continues to its completion by the remaining players. Likewise, if the Grab It marble 8 is erroneously captured by a player who has not yet captured all of his designated Grab marbles 7 , the game is stopped while said player returns the Grab It marble 8 to the arena playing field and said player is not permitted to continue the game in play, which game then continues to its completion by the remaining players.
[0043] The above described game and apparatus providing for the play thereof, is particularly valuable in teaching eye-hand coordination for younger, smaller children and others needing such development. The different colors provided for the different groups of Grab marbles 7 and their associated Grabber tools 4 , are easily recognized by younger children. No specific number of playing marbles is required, as the game may be played with a relatively few for smaller children, and more added for more advanced play. The use of safe plastic materials with smoothly rounded borders devoid of sharp edges provides a safe game apparatus and other game parts. It must be noted, however, any particular material used in making any element of the disclosed game invention does not represent a limitation to the scope of such disclosure. The arena could be made of wood or metal or cardboard, or any other relatively rigid material, as well as plastic. The same is true of the marbles used and disclosed herein. Also, the Grabber tool 4 could be made with wood or metal or a combination thereof. Any preference for plastic is for practical reasons as to expense and ease (and speed) of manufacture, in addition to permitting “smoothly rounded borders devoid of sharp edges.”
[0044] FIGS. 9-13 address containment, for portability and storage, of the invention game and its components. While the Brief Description of the Drawings, above, describe one means and design(s) for use in such containment, other means and designs are included in the scope of the invention and the figures specific to this purpose are not intended in any way to be limiting on the scope of the claimed invention. For example, one alternative (to FIG. 11 ) means for storing or containing the individual players (similar colored) marbles is to package them within each respectively colored (or otherwise similarly designated) Grabber tool. In this instance the Grabber tools could be contained, in a fixed or unfixed manner, within the larger container for (or, operating as) the playing arena. It is to be understood that the invention lies in the scheme of the game and its uniquely designed elements to achieve the goal of pleasure and enjoyment in playing the game while achieving the purpose of enhancing children's manual dexterity and eye-hand coordination at the same time.
[0045] Therefore, the present invention is not limited to any particular embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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An improved game for teaching manual dexterity and improving eye-hand coordination using tools appropriate for very small children to hold and operate is disclosed. Moreover, an improved simplified marble game for teaching rule-following for very young children to provide a transition to more difficult and more complicated games as they age is disclosed herein.
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TECHNICAL FIELD
[0001] The present invention relates generally to the field of quantum computing, and more particularly, to a quantum computing device and method including qubit arrays of entangled atomic states using negative refractive index lenses. In addition, a three-dimensional architecture is provided.
DESCRIPTION OF THE RELATED ART
[0002] Quantum information processing covers a variety of fields where quantum mechanical effects are used to process information in applications such as computation and communications.
[0003] Quantum computation involves manipulation of data in the form of quantum bits or “qubits.” In contrast to classical computation, where a bit of information is used to represent only one of two possible logic states, namely a “1” or a “0,” in quantum computation, a qubit can represent both logical states simultaneously as a superposition of quantum states. This property gives rise to powerful computational parallelism. Algorithms that exploit this parallelism have been developed, e.g., for efficiently factorizing large composite integers.
[0004] Since the concept and advantages of quantum computing were introduced in the 1990's, a large number of concepts for qubits have been proposed and tried with limited success. Proposed concepts have included systems based on moving quasi-particles around lattices, semiconductor-based systems having quantum wells and optical-resonator-based systems. The development of quantum computing brings about a need for physical qubits that are easily entangled, but individually addressable and initializable.
[0005] A generally recognized problem is that quantum computation, and indeed any system involving sensitive information processing, requires a quiet electromagnetic environment to operate. If the system interacts with the environment, it may lose coherence and quantum parallelism may be destroyed.
SUMMARY OF THE INVENTION
[0006] According to the present invention, a quantum computing device includes qubits that can be controlled and entangled with minimum interaction with external sources. The quantum computing device includes qubits that include at least a pair of neutral atoms and a negative index lens disposed between the pair of neutral atoms. Negative index metamaterials and perfect lenses are used to provide entanglement in neutral atoms.
[0007] One aspect of the disclosed technology relates to a qubit for use in a quantum computing system. The qubit includes a pair of atoms and a negative index lens disposed between the pair of atoms.
[0008] According to another aspect, the negative index lens is arranged to entangle states of the pair of atoms.
[0009] According to another aspect, the qubit includes a second negative index lens disposed adjacent to one of the pair of atoms and a third atom disposed adjacent to the second negative index lens.
[0010] According to another aspect, a qubit array includes a plurality of qubits.
[0011] According to another aspect, the plurality of qubits is arranged in a two-dimensional architecture.
[0012] According to another aspect, the plurality of qubits is arranged in a three-dimensional architecture.
[0013] Another aspect of the disclosed technology relates to a quantum computing method that includes disposing pairs of neutral atoms on opposite sides of negative index lenses, selectively exciting the atoms, selectively energizing and de-energizing the negative index lenses, the selectively energizing and de-energizing facilitating entanglement of states of the atoms, and interrogating the atoms to determine the state of at least one of the neutral atoms.
[0014] Another aspect of the disclosed technology relates to a quantum computing device that includes a plurality of neutral atoms, each pair of neutral atoms being separated by a negative index lens, wherein each pair of neutral atoms and negative index lens are arranged to define a quantum bit, and control circuitry operatively coupled to one or more excitation sources, wherein the control circuitry and one or more excitation sources cooperate to entangle the quantum bits.
[0015] Another aspect of the disclosed technology relates to a quantum computing device that includes an array of elements, where each element of the array includes a first neutral atom, a second neutral atom, and a negative index lens disposed between the first and second neutral atoms. The first and second neutral atoms are arranged to define first and second basis states of a quantum bit, and the elements are arranged so as to cause entanglement of the quantum bits of the elements of the array.
[0016] To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
[0017] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a functional block diagram of a quantum computing device in accordance with one embodiment of the disclosed technology;
[0019] FIG. 2 is a functional block diagram of a quantum processing unit in accordance with one embodiment of the disclosed technology;
[0020] FIG. 3 is a diagrammatic illustration of a qubit in accordance with one exemplary embodiment of the disclosed technology;
[0021] FIG. 4 is a diagrammatic illustration of a qubit in accordance with another exemplary embodiment of the disclosed technology;
[0022] FIG. 5 is a diagrammatic illustration of a qubit array in accordance with an exemplary embodiment of the disclosed technology;
[0023] FIG. 6 is a diagrammatic illustration of a qubit array in accordance with an exemplary embodiment of the disclosed technology;
[0024] FIG. 7 is a diagrammatic illustration showing operation of an exemplary qubit array;
[0025] FIG. 8 is a diagrammatic illustration showing operation of an exemplary qubit array; and
[0026] FIG. 9 is a flow chart or functional diagram representing a quantum computing method in accordance with one aspect of the disclosed technology.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In the detailed description that follows, like components have been given the same reference numerals regardless of whether they are shown in different embodiments of the present invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form.
[0028] One aspect of the disclosed technology includes a quantum computing device having quantum bits (“qubits”) that can be controlled and entangled with minimum interaction with external sources. As is described in more detail below, the quantum computing device makes use of a negative index material (“NIM”) to construct a negative index lens. The negative index lens is disposed between pairs of neutral atoms to provide entanglement or otherwise controllably couple the neutral atom qubits.
[0029] FIG. 1 illustrates an example of a suitable computing system environment 10 (also referred to as a quantum computing system, a quantum computing device or a quantum computer) in which aspects of the disclosed technology may be implemented. The computing system environment 10 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the disclosed technology. Neither should the computing environment 10 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 10 .
[0030] Aspects of the invention are operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of such computing systems, environments, and/or configurations that may be suitable for use with aspects of the invention include, but are not limited to, personal computers, server computers, hand held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any suitable system component or device, and the like.
[0031] With reference to FIG. 1 , an exemplary system for implementing aspects of the invention includes a general purpose computing device in the form of a computer 10 . Components of the computer may include, but are not limited to, a processing unit, e.g., a quantum processing unit 12 , a system memory, e.g., a general or conventional system memory 14 and/or a quantum memory 16 , and a system bus 18 that couples the various system components, including the system memory (or memories), to the processing unit 12 . The system bus 18 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus and a local bus using any of a variety of bus architectures.
[0032] In the illustrated embodiment, conventional memory 14 may be representative of the overall hierarchy of memory devices containing software and data used to implement the functionality of the computer 10 . The memory may include, for example, RAM or other volatile solid-state memory, and/or other non-volatile solid-state memory, a magnetic storage medium such as a hard disc drive, a removable storage medium or other suitable storage media. As illustrated, the memory 14 may store drivers 20 , e.g., I/O device drivers, application programs 22 , an operating system 24 and application program data 26 .
[0033] In addition, user input interface(s) 30 may couple a variety of user input devices 32 , e.g., a mouse, a keyboard, a microphone, a gamepad or the like, to the processing unit 12 via the bus 18 . In addition, a display such as a monitor 34 or other suitable display device may be connected to the system bus 18 via an interface, such as a video interface. In addition to the monitor, the computer may also include other peripheral output devices, which may be connected through an output peripheral interface 38 .
[0034] The computer 10 may operate in a network environment using logical connections to one or more remote computers, e.g., personal computers, servers, routers, network PCs, peer devices or other common network nodes.
[0035] Turning now to FIG. 2 , aspects of the invention will be discussed with respect to a quantum processing unit 12 and/or quantum memory 16 that includes a qubit or qubit array that is configured to provide sufficient entanglement for use in quantum computing operations. As illustrated, the qubit array 40 may be operatively coupled to suitable control circuitry 42 that cooperates with or otherwise controls, one or more excitation sources 44 , e.g., laser sources or sources of electric or magnetic fields, and one or more atomic state readers 46 . As is discussed more fully below, the qubit array 40 , control circuitry 42 , excitation source 44 and atomic state reader 46 cooperate to provide physical qubits that may be entangled as well as individually addressed and set or reset for use in quantum computation processes.
[0036] Turning now to FIG. 3 , a quantum bit (“qubit”) 50 is illustrated. In one embodiment, the qubit 50 includes a pair of atoms 52 , e.g., neutral atoms, separated by or otherwise disposed on opposite sides of a negative index lens 54 . The provision of a negative index lens between a pair of atoms, e.g., neutral atoms, is believed to provide a physical qubit that is easily entangled, while still being individually addressed. As is discussed more fully below, the qubit (or qubit arrays) may take one of a variety of different configurations, geometries, properties or the like, without departing from the scope of the present invention.
[0037] In a preferred embodiment, the negative lens is comprised of a negative index material (“NIM”), thereby being constructed as a NIM “perfect lens.” One example of a suitable perfect lens, as well as a description of the operative properties, may be found in J. B. Pendry and S. A. Ramakrishna “Near Field Lenses in Two Dimensions,” J. Phys. [Condensed Matter] 14 1-17 (2002), which is incorporated herein by reference in its entirety. In the embodiment illustrated in FIG. 3 , the negative index lens is depicted as having a thickness d, while the atoms 52 are depicted as being separated by a distance 2d. In this configuration, the optical path length between the atoms is zero. This means that the left atom's (e.g., atom A's) wave function, e.g., spin down|0>A, is combined with the right atom's (e.g., atom B's) wave function, e.g., spin up|1>B, to yield a single product wave function, e.g., |0>A|1>B, that describes the two-atom system occurring at both points (e.g., point A and point B).
[0038] Further, the distance between the two focal points of the negative index lens is d(1−n), where n is the refractive index of the negative index lens. It will be appreciated that the thickness d of the negative index lens will depend on a variety of factors, including, the negative index material from which the negative index lens is constructed, e.g., the index of refraction associated with the given negative index material, the types of atoms used in the qubit and the like.
[0039] In a preferred embodiment, the negative index lens 52 is constructed from a suitable negative index material, e.g., a metamaterial. It will be appreciated that metamaterials are understood to include materials or objects that gain (electromagnetic) material properties from their structure rather than inheriting then directly from the material of which it is composed. Metamaterials often are associated with material properties not found in naturally-formed substances.
[0040] In a preferred embodiment, the qubit 50 will include or otherwise make use of neutral cesium (Cs) atoms. One advantage associated with the use of Cesium atoms stems from the fact that the Cs atom has a pair of states that are separated by a transition energy equivalent to a 9.2 GHz (GigaHertz) photon. Of course, each qubit may include or otherwise make use of other atoms, e.g., other neutral atoms, alkaline atoms, exotic atoms and the like. Nonlimiting examples of suitable atoms include hydrogen, rubidium and positronium.
[0041] Turning now to FIG. 4 , an alternative embodiment of a qubit 50 is illustrated. In this embodiment, the qubit includes a pair of negative index lenses 54 , which are disposed between or otherwise separate pairs of atoms 52 e.g., neutral atoms. As is discussed with respect to FIG. 3 , the qubit 50 may include or otherwise make use of a variety of atoms, such as neutral atoms or neutral alkaline atoms, e.g., neutral cesium atoms. In addition, as is discussed above, if a given negative index lens has a thickness of d, in the case of a “perfect lens” the atoms on opposite sides of the negative index lens 54 may be spaced apart by a distance of 2d.
[0042] Regardless of the particular qubit configuration being employed, multiple qubits may be arranged in or otherwise used to construct qubit arrays, where the qubits may be entangled, initialized or modified, and addressed. FIG. 5 illustrates an exemplary qubit array 40 arranged in accordance with the principles of the disclosed technology. The exemplary qubit array 40 includes a plurality of negative index lenses 54 , where each negative index lens separates a pair of atoms 52 , e.g., neutral atoms. In the illustrated embodiment, the qubit array also includes a pair of negative mirrors 56 , e.g., mirrors constructed of a negative index material, thereby providing “perfect mirrors,” at the ends of the array. The provision of negative index mirrors 56 at the ends of the array 40 provide for an optical path length of zero between the respective end atoms 52 and the respective negative index mirrors 56 . As is discussed below, the qubit array is believed effective in providing entangled qubits in conjunction with the capability of modifying and reading individual qubits.
[0043] The qubits and qubit arrays discussed herein may be arranged in a variety of useful and scalable architectures. For example, the qubit array may take on the form of a one-dimensional qubit array (illustrated, for example, in FIG. 5 ). Alternatively, as is illustrated in FIG. 6 , the qubit array 40 may be extended into two dimensions. Further, the qubit array is believed to be extendable into three dimensions, where the three-dimensional qubit array would be structured in a manner similar to that with respect to FIG. 6 only including a third dimension, for example a dimension having atoms and negative index lenses extending into or out of the plane on the page on which FIG. 6 is illustrated. While setting and reading of the atoms and lenses may be complex in a three-dimensional qubit array, it is believed that these complexities may be overcome by design considerations if a three-dimensional array is required, e.g., by the provision of a suitable array of optical fibers or cables or free special lasers used in conjunction with an array of mirrors to direct energy to desired locations. Of course other configurations operable to selectively and controllably direct energy, e.g., electromagnetic energy, to a variety of locations may be employed.
[0044] Turning now to FIG. 7 and FIG. 8 , an exemplary qubit array is illustrated schematically showing various aspects of exemplary control circuitry, excitation sources 44 , atomic state readers 46 and lens control circuitry 58 . In the illustrated schematic embodiment, excitation signals, e.g., signals used to controllably modify individual qubits, may be generated by suitable excitation sources, for example, a source providing 9.2 GigaHertz (GHz) signals used to excite, for example, cesium atoms. The excitation signals may be provided to modify the atoms as required by a given programming algorithm using 9.2 GHz signals. In addition, lens control signals may be generated by an appropriate excitation source, e.g., a suitable laser source or sources together with optical fibers or arrays of mirrors to controllably direct the energy to selected negative index lenses, or a source of electric or magnetic field sources. One advantageous property of the herein-discussed negative index mirrors is that the negative index mirror may be switched between negative index material properties and positive index material properties upon the application of appropriate electromagnetic excitation or electromagnetic control. The device illustrated in FIG. 7 also includes an atomic state reader 46 , which may be used to read the qubits and atoms within the qubits, for example, by determining the state, e.g., a spin-up state or a spin-down state or some superposition of the spin-up state and spin-down state. While the excitation source 44 and atomic state reader 46 are schematically illustrated as separate units, it is to be appreciated that the related functionality may be embodied in a single unit capable of controllable modifying and reading the individual qubits.
[0045] FIG. 7 schematically illustrates initializing or programming the qubits using the excitation source. In addition, FIG. 7 illustrates energizing or otherwise activating one or more of the negative index lenses 54 to bring about a “negative index off” state, thereby transitioning the lenses 54 to a positive index material state.
[0046] FIG. 8 illustrates the qubit array of FIG. 7 when the negative index lenses are returned to their negative index material state. By activating the negative index lenses and then deactivating the negative index lenses, the states of the atoms within the qubit array may be entangled. FIG. 8 illustrates the qubit array where the negative off mechanism has been removed along with removal of 9.2 GHz modification signals. The system can then be viewed as being isolated. At this stage, the atoms may be interrogated to determine their states. Stated differently, a quantum computing device employing the above-described qubits and qubit arrays may be operated by initializing the atoms in a set of states, selectively activating and/or deactivating the negative index lenses to initiate a type of quantum evolutionary calculation and interrogating the atoms again after a certain amount of time to obtain a result.
[0047] While for purposes of simplicity of explanation, the flow charts or functional diagram in FIG. 9 include a series of steps or functional blocks that represent one or more aspects of the quantum computing device employing the herein described qubits and/or qubit arrays, it is to be understood and appreciated that aspects of the invention described herein are not limited to the order of steps or functional blocks, as some steps or functional blocks may, in accordance with aspects of the present invention occur in different orders and/or concurrently with other steps or functional blocks from that shown or described herein. Moreover, not all illustrated steps or functional blocks representing aspects of relevant operation may be required to implement a methodology in accordance with an aspect of the invention. Furthermore, additional steps or functional blocks representative of aspects of relevant operation may be added without departing from the scope of the present invention.
[0048] Turning now to FIG. 9 , an exemplary quantum computation methodology is illustrated in terms of functional blocks. At functional block 100 , some atoms within the qubit array are excited using a suitable excitation source, for example, in the case of cesium atoms, a source capable of generating 9.2 GHz signals. As is discussed above, the individual qubits within the qubit array may be modified as required by a suitable programming algorithm.
[0049] At functional block 105 , the negative index lenses are activated or otherwise energized, for example, using a suitable lens control source, such as an array of lasers and mirrors positioned to controllably and selectively activate or de-activate the negative index lenses and mirrors.
[0050] At functional block 110 , the negative index lenses are deactivated or otherwise returned to their negative index material properties thereby entangling the states of the qubits within the qubit array. At functional block 115 , the qubits or atoms within the qubit array may be probed or otherwise interrogated to determine their current state, e.g., a spin-up state, a spin-down state, or some superposition of a spin-up state and a spin-down state.
[0051] Stated more simply, operation of the qubit array disclosed herein includes placing the atoms within the qubit array within a set of states, e.g., in accordance with a predetermined programming algorithm, using selective activation of the negative index lenses to initiate a type of quantum evolutionary calculation, and probing or interrogating atoms within the qubit array after a certain amount of time to obtain a result.
[0052] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
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A quantum computing device and method employs qubit arrays of entangled states using negative refractive index lenses. A qubit includes a pair of neutral atoms separated by or disposed on opposite sides of a negative refractive index lens. The neutral atoms and negative refractive index lens are selectively energized and/or activated to cause entanglement of states of the atoms. The quantum computing device enjoys a novel architecture that is workable and scalable in terms of size and wavelength.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Application Ser. No. 60/625,734, filed Nov. 4, 2004, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The inventive subject matter relates generally to information and communication systems, and more particularly to methods, apparatuses, and software for storage and distribution of real estate related data.
BACKGROUND
[0003] Real estate agent tools for finding and marketing available properties are generally text based and include minimal photos provided in a linear result list sorted by price. To access more information about a property, the agent, buyer, or other person performing a search must ‘drill down’ through a series of web pages, clicking several times, spawning new web pages for viewing maps, school district, tax, and other information.
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 illustrates example embodiments of the present subject matter.
[0005] FIG. 2 illustrates example software application interfaces.
[0006] FIG. 3 is an interface screen view displaying an example 3D detail of a landscape of a selected real estate property.
[0007] FIG. 4 illustrates one example of a 3D landscape display 400 for multiple selected properties.
[0008] FIG. 5 is a view illustrating generally one example of a web-based geographic map display and corresponding hand-held GPS locator.
[0009] FIG. 6 is an interface screen view illustrating generally one example of category tools.
[0010] FIG. 7 is an interface screen view illustrating generally one example of filtering tools.
[0011] FIG. 8 is an interface screen view illustrating generally one example of spatial location software tools.
[0012] FIG. 9 is an interface screen view illustrating an example of real estate property information obtained from a real estate listing service.
[0013] FIG. 10 is an interface screen view illustrating an example of a keyword search tool.
[0014] FIG. 11 illustrates a screen view of a keyword search result in view of an address.
[0015] FIG. 12 illustrates an example 3D detail of a landscape view for multiple user-selected school properties.
[0016] FIG. 13 is an interface screen view illustrating an example 3D detail of a landscape according to user-specified criteria.
[0017] FIG. 14 is an interface screen view illustrating an example 3D detail of a landscape and displayed distances between user-selected locations.
[0018] FIG. 15 illustrates an example embodiment of a system on which the subject matter hereof can be practiced.
[0019] FIG. 16 is schematic illustrating an example embodiment of a GeoPoints network architecture.
[0020] FIG. 17 is schematic illustrating a Client Connectivity Manager architecture.
[0021] FIG. 18 is schematic illustrating an example embodiment of a GeoPoints system architecture.
[0022] FIG. 19 is schematic illustrating an example client architecture.
DETAILED DESCRIPTION
[0023] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventive subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized and that structural, logical, and electrical changes may be made without departing from the scope of the inventive subject matter. Such embodiments of the inventive subject matter may be referred to, individually and/or collectively, herein by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed.
[0024] The following description is, therefore, not to be taken in a limited sense, and the scope of the inventive subject matter is defined by the appended claims.
[0025] The functions or algorithms described herein are implemented in hardware, software or a combination of software and hardware in one embodiment. The software comprises computer executable instructions encoded in a computer readable media. Further, such functions correspond to modules, which are software, hardware, firmware, or any combination thereof. Multiple functions are performed in one or more modules as desired, and the embodiments described are merely examples. The software is executed on a digital signal processor, application-specific integrated circuit, microprocessor, or other type of processor operating on a system, such as a personal computer, server, a router, or other device capable of processing data including network interconnection devices.
[0026] Some embodiments are implement the functions in two or more specific interconnected hardware modules or devices with related control and data signals communicated between and through the modules, or as portions of an application-specific integrated circuit. Thus, the exemplary process flow is applicable to software, firmware, and hardware implementations.
[0027] FIG. 1 illustrates example embodiments of the present subject matter. For example, FIG. 1 illustrates various embodiments of that include real estate related systems and software that facilitate retrieval and display of information related to properties for sale. This information can include properties for sale, pictures, location, maps, tax data, neighborhood and school information, voting data, census data, title or deed data, and virtually any other data related to real estate. These and other embodiments can operate on a personal computer, such as a desktop or laptop personal computer, on a mobile device, such as a personal digital assistant 130 , a mobile telephone, other mobile computing device, or virtually any other computing device capable of receiving input, processing and retrieving data, and generating output. Such embodiments utilize a tight integration of Virtual Reality (VR), Geographic Information Systems (GIS), Location-Based Services (LBS) and real-time datasets.
[0028] For example, some embodiments combine aerial photography 110 into a game-style engine that enables a user to fly around a 3D environment and view high-resolution images and terrain definitions. Some such embodiments include a search engine that directly queries one or more real estate listing service databases, such as Regional Multi-Listing Service (“RMLS” or “MLS”) databases to generate a real time display of available properties integrated within the 3D environment. When a user types in a search query, such as a query based on zip code, property type, price range, or other real estate feature, location results are displayed in a listing, populated automatically into a 3D map terrain display, or both. In some embodiments, corresponding property photographs are retrieved from an MLS database and are displayed directly over the property on a 3D map terrain. This display can also include the pictured property's postal address or other data associated with or otherwise related to the property.
[0029] Embodiments including the 3D map terrain quickly provide the user with a spatial sense of available property. Some embodiments also display items such as roads, schools, hospitals, fire stations, shopping, parks and open space, public transit, and other items displayable on a map. This allows the searcher to visualize the available property in relation to these other items.
[0030] FIG. 2 illustrates example software application interfaces 200 . These interfaces include standard real estate and mapping tools and a terrain visualization application 212 according to one embodiment of the present subject matter. In one embodiment, the terrain visualization application 212 uses one or more industry standard tools, including real estate listing systems such as Realtor.com 210 for property searching, Mapquest.com 211 for property mapping. These tools are integrated with a terrain visualization application 212 , which provides a “virtual helicopter” type view. This provides a real estate agent, or other user, with a tool to rapidly identify, locate, and filter properties according to user-selected criteria, visualization, and other user preferences.
[0031] Once the user selects a geographic area with suitable properties, further detail about the area can be obtained by moving closer, or zooming in, to the desired location. In some embodiments, further detail can also be obtained by selecting points of interest, such as with a computer mouse or other suitable device. In some embodiments, the right-hand side of the display 200 adapts upon area or property selection to provide a more detailed listing of available properties 215 , while the left-hand side can display an image of a selected property 216 .
[0032] FIG. 3 is an interface screen 300 view displaying an example 3D landscape detail of a selected real estate property and neighborhood GeoPoints.
[0033] A GeoPoint models a point on the earth. In general, each GeoPoint is spatially recorded based on an eight degrees of freedom (“8DOF”) (latitude, longitude, altitude, pitch, roll, yaw, direction, speed) representation and this positional accuracy enables GeoPoints to be differentiated and displayed in 3D coordinate space. However, other embodiments include fewer or greater degrees of freedom representations. Some GeoPoints broadcast, or otherwise make available upon request, via wireless and wired network technology information about the GeoPoint. For example, a GeoPoint at a neighborhood coffee shop can provide information such as a menu, location, schedule of events, via photos, audio, video, text, or other information via a digitally transmitted medium. Further information regarding GeoPoint technology is provided below under heading “GeoPoint System Architecture.”
[0034] Selected real estate properties and neighborhood GeoPoints are not limited to real estate properties available for purchase, but can also include, without limitation, schools, businesses, parks, government facilities, hospitals, and the like. All selected real estate property and GeoPoint information can be available on demand in real-time via a network or from the GeoPoints and can be continuously or intermittently updated, for example, by other users or business owners. In other embodiments, the selected real estate property and GeoPoint information is read in whole, or in part, from a computer readable medium, such as a compact disc or digital versatile disc.
[0035] A selected real estate property or GeoPoint can be a stationary object, such as a building, business, web cam, or sensor, or it can be a moving object such as a person or vehicle. For example, the interface screen 300 can show additional pertinent information in relation to the selected property of interest 316 , such as shopping, restaurants, or parking 320 . In the present example, the right hand side of the interface screen 300 further displays the selected property 316 and a traffic-cam 310 directly feeding live images into the immersive environment.
[0036] FIG. 4 illustrates one example of a 3D landscape display 400 for multiple selected properties. Supplementing traditional MLS searching and spatial displays, the 3D landscape display 400 software application provides advanced geographic information system (“GIS”) tools to filter and map locations. The illustrated 3D landscape display 400 shows three circles, each centroid determined according to user-specified location or criteria. In the present example, one location can be where a client or user wants to reside 416 , the second a client workplace 417 , and a third a spouse's workplace, school, or other user-designated location 418 . The user can filter out the areas not within the one or more circular areas, or limit display to only the intersection of the three circles. As a union set, the circles can establish a sorting priority, adjustable by the user by “pulling” the designated markers 420 A, 420 B, 420 C at the center of each circle to expand or reduce the area of interest.
[0037] FIG. 5 is a view illustrating generally one example of a web-based geographic map display and corresponding hand-held GPS locator. This view includes one example of a web-based geographic map display 512 and corresponding commercially available hand-held GPS locator 510 operatively coupled to a personal digital assistant 511 . Although a personal digital assistant 511 is illustrated, the personal digital assistant 511 can be any mobile computing device including a next generation PDA or cell phone with broadband and mapping GPS capabilities to display search related information directly on a screen of such a device or for driving directions to and from selected locations. A “Send List” function is included to provide information corresponding to a selected property or area of interest through e-mail, text message, or other message type to the client. In some embodiments, when such a message is received by a client, or other recipient, the client or other recipient is able to click, or otherwise select or copy and paste, a link provided in the message to view information about the selected property or area of interest. The other information can include directions, a 3D landscape display of the selected property or area of interest, pictures thereof, or other information pertinent to the selected property or area of interest.
[0038] The geographic map display 512 is a part of a software application that is operative on the personal digital assistant 511 , or other suitable device. The software application accommodates maximum flexible robustness. In one embodiment, the shell application is encoded in C++ to take advantage of web services to populate and fill out menus, search and query toolsets and other display mechanisms. This enables a fast and efficient use of available web-based technologies and formats for images, text, audio, video, and streaming information. Datasets and other modules provided in other embodiments include user authentication, security, third party integration, and eXtensible Markup Language (“XML”) data transfer. However, other suitable programming languages, media types, and data transfer protocols and mechanisms can be used.
[0039] According to still other embodiments, the user interface can be modified to customize or enhance the overall look and feel of the application. The user interface can also be modified for specific client computing device types, such as a user interface targeted at commodity PCs with lower amounts of memory and lower processing speed rather than high end workstations with larger memories and faster processors. Other enhancements can be made to the user interface to meet specific needs of the computing environment such as improved memory management techniques employed to optimize speed for certain client computing device types, caching mechanisms. Yet further customization and enhancement can be performed to target user types, such as generating more user friendly search tools and interfaces. Other embodiments include modified user interfaces based on access rights for security purposes or subscription based purposes.
[0040] According to yet another example embodiment, a method to extrapolate multi-resolution terrain and imagery data within a small memory footprint is provided. In some locations data is available at a 6-inch resolution and can quickly become terabytes of information causing data overload for most field applications. Accordingly, data compression and extrapolation based on wavelet or other techniques can be used to compress the data to avoid data overload or to decrease system and network latency.
[0041] Yet other example embodiments provide modules to integrate MLS databases with a Client Connectivity Manager (“CCM”). Integration, for instance, can involve integrating MLS data via parsing XML into the CCM databases. In the event that web services become available to access MLS data, streamlined modules are provided to interface with 3 rd party web services as part of the CCM rather than data dumps via FTP and XML.
[0042] According to another example embodiment, the web services components are integrated into a C++ 3D Engine to access properties or locations of interest and subsequent MLS data that may be available via 3 rd party web services. In some embodiments, interfacing of the 3D engine with the enterprise system occurs by combining managed and unmanaged source code within the Microsoft .NET framework. This allows the user to interact with spatial data within a 3D environment, perform spatial queries, contextual queries, and provides a suite of user friendly 3D analytical tools based on various GIS approaches.
[0043] According to another example embodiment, a CCM provides a set of communication tools based on existing TCP and UDP protocols developed using C++ to support client/server interaction. The CCM is composed of a Communications Manager, an Administrative Manager, a User Preferences Manager, and an Accounting Manager. The Communications Manager handles network and delivery protocols, supports multi-user activity, and requests information from the database. The User Preferences Manager monitors user preferences and customizes user requests for data based on properties or locations of interest within a client awareness buffer. The Accounting and Administrative Managers track permissible user data requests and calculates accounting information based on data access. The CCM is also responsible for handling client position, client data requests from remote servers, client login authentication, data encryption when transmitting between the mobile client and the CCM server, and updates the client-side property or location of interest display. Also provided is an API for the client-side applications that can connect to the CCM server.
[0044] The CCM continuously monitors the client location and performs spatially constrained data requests to the database server. The enterprise GIS database is built, in one example embodiment, on Oracle Spatial, accessed through Arc Spatial Data Engine (“SDE”) and an object-relational geodatabase, both of which are available from ESRI of Redlands, Calif. Both spatial and multimedia data are stored as objects. Spatial search and query functions are passed from the client through the CCM to the GIS. Using the location information of the client, data for the nearest available relevant GeoPoints are retrieved from the database and routed directly to the requesting client or routed through the CCM. A GeoPoint models a point on the earth. In general, each GeoPoint is spatially recorded based on an eight degrees of freedom (“8DOF”) (latitude, longitude, altitude, pitch, roll, yaw, direction, speed) representation and this positional accuracy enables GeoPoints to be differentiated and displayed in 3D coordinate space. However, other embodiments include fewer or greater degrees of freedom representations. The database, in some embodiments, is an Oracle Spatial running on Linux Advanced Server and integrated with ArcObjects, which is also available from ESRI of Redlands, Calif. The CCM provides client access to the media object attached to the GeoPoints and stored in the Oracle database. Access to this information is performed via a database API, such as the Oracle C++ Call Interface (“OCCI”) for direct retrieval of non-GIS data. For GIS analysis, the CCM provides GeoPoint data access for GIS analysis via ArcSDE.
[0045] Thus, according to various embodiments, the present subject matter provides for the integration of real-time MLS datasets directly into the system hereof, along with high resolution 3D terrain imaging, and sophisticated GIS tools for property location. Finally, the system hereof can integrate GeoPoint technology which enables full images, text, audio, video or live streaming data from webcams, sensors and so on directly embedded into the user's desktop or mobile computer application.
[0046] According to still additional embodiments illustrated in the user-interface screen displays of FIGS. 6-8 , the present subject matter can provide high-resolution aerial imagery of major metropolitan areas, some or all of which can be color or monochromatic imagery. Various features provided include:
Visualize houses and their neighborhoods using flight simulation capability Map house locations with full MLS property information High-resolution aerial imagery for your real estate market Sophisticated search, select, and display capabilities for all MLS properties Display roads, schools, hospitals, and work-places for enhanced property searches Email MLS information and images directly to clients for immediate impact Calculate distances between features. Create distance buffers around schools, day-care, and workplace to target your client's ideal property selections.
[0055] FIG. 6 is an interface screen view 600 illustrating generally one example of category tools. This view provides user-selectable address-base searching 616 and further providing additional categories 610 for display in relation to an address of interest. Information pertaining to selected display categories 610 may be limited by distance 611 A-C according to user preference.
[0056] FIG. 7 is an interface screen view 700 illustrating generally one example of filtering tools. In some embodiments, selection of one or more GeoPoint fields from the interface screen view 700 causes the selected GeoPoints to be displayed to a user. In some embodiments, user-selected filtering is in relation to the address-based search request.
[0057] FIG. 8 is an interface screen view 800 illustrating generally one example of spatial location software tools. The user is provided a window, for example where a postal address can be used and where display of additional GeoPoint categories, such as categories 610 of FIG. 6 , may not be desired or display filtering, as illustrated and described with regard to FIG. 7 , may be unnecessary.
[0058] FIG. 9 is an interface screen view 900 illustrating an example of real estate property information obtained from a real estate listing service. In some embodiments, the real estate listing service is a regional Multiple Listing Service (“RMLS”). The interface screen view 900 can be retrieved from a result listing following a query, such as a user-initiated address-based search related to currently marketed real estate property.
[0059] FIG. 10 is an interface screen view 1000 illustrating an example keyword search tool 1015 . In some embodiments, the keyword search tool 1015 is used in relation to another search such as a spatial search 1016 , for example. The interface screen provides additional categories for display 1010 in relation to the keyword search tool 1015 . Additional search options such as ownership or certain real estate characteristics 1017 and general location 1018 are provided.
[0060] FIG. 11 illustrates a screen view 1100 of a keyword search result in view of an address. The keyword search result in other embodiments can be in view of multiple addresses. In some embodiments, other geographic locations can be used in place of the address, such as an area or a GeoPoint.
[0061] According to other embodiments, the system is connected to a national real estate listing service database to obtain current property information and provides sophisticated navigation tools to view ‘neighborhoods-at-a-glance’. Full search and select features with distance and buffer capability for enhanced property selection can be provided. Other features that are included in various embodiments include:
Full national MLS property descriptions and images. High-resolution aerial color and/or monochromatic imagery. Use “neighborhood-at-a-glance” to see properties in their neighborhood context. Visualize properties and their neighborhoods using powerful over-flight capabilities. Display road, schools, hospitals, and work-places. Email MLS information and GeoRealtor images directly to clients. Calculate distances between properties, day care, schools, and workplaces. Generate distance buffers around selected schools and workplaces to maximize potential property selections. Full search and select capabilities for MLS properties with sophisticated search by location features. Map selected properties with accurate driving directions. Extensive printout capabilities for MLS property information, maps, and aerial imagery. Mouse over floating thumbnails to display MLS data. Location enhancement capability allows user to refine property locations. Insert and view multimedia information including photos, audio, movies, virtual tours of properties, and web links. Integrated web capability.
[0077] FIG. 12 illustrates an example 3D detail of a landscape view 1200 for multiple user-selected school properties. The landscape view 1200 displays landscape and terrain information 1210 in response to a search, such as an address-based search. The landscape view 1200 , further displays information related to user specified categories, such as restaurants, schools, and other GeoPoints.
[0078] FIG. 13 illustrates one example of an interface screen 1300 displaying landscape and terrain information 1310 for the intersection of three circles 1315 , each centroid 1316 A-C determined according to different user-specified criteria.
[0079] FIG. 14 illustrates one example of an interface screen 1400 displaying landscape and terrain information 1410 and optional distances 1411 between user-specified locations 1415 A-C, or location determined according to user-specified criteria. The interface screen 1400 further includes a GeoPoint display options interface 1416 . This interface allows a user to cause user specified GeoPoints to be identified within landscape and terrain information 1410 .
[0080] In various embodiments, the interfaces are provided to users on platforms including Microsoft Windows, Linux, Mac O/S, Unix, Palm O/S, and other platform operating systems. In some embodiments, the interface is provided in a web browser such as Microsoft Internet Explorer, Netscape Navigator, Fire Fox, OpenWave, or other web browser.
GeoPoint System Architecture
[0081] FIG. 15 illustrates one example embodiment of a system on which the subject matter hereof can be practiced. This system delivers real-time information in an Enhanced location based service (“LBS”) environment that is intelligent and spatialized via a network of GeoPoints virtually embedded within the physical fabric of the real world. This enhanced environment 1510 can include one or more elements from such systems as GIS (Burrough & McDonnell, 1998; Chrisman, 2001; Clarke, 2002; DeMers, 1999; Longley et al., 1999), GPS (Kennedy, 1996; Trimble, 2002), LBS (LBSZone, 2002; 3gLocate.com, 2003; VanderMeer, 2002), wireless (Sprint, Inc., 2003; Shen, 2003), machine vision (BMVA, 2002; Machine Vision Group, 2003), and AR (Azma, 1997; Julier, 2000; Piekarski et al., 1999; Thwaites & Addison, 2201; Fisher & Unwin, 2002). (It is noted for the avoidance of doubt that none of the foregoing systems/publications or ones enumerated below are admitted to be prior art to the present application solely as a result of being listed herein.) According to one embodiment, these applications 1520 are grouped into modules, 1) GeoPoints Network 1521, 2) Human Computer Interface 1522, 3) Mesh-Flocking System 1523, and 4) GIS Functionality 1524. The modules have extended application 1530 for Homeland Security, natural disaster management, education and research, enterprise commerce, and for government agencies, among other application.
[0082] FIG. 16 illustrates one example embodiment the present subject matter. GeoPoints are loosely based on traditional GPS waypoints obtained from GPS satellites 1640 A-C, possessing latitude, longitude, altitude and metadata information for point-of-interest wayfinding markers. In addition, GeoPoints, in some embodiments, also have attributes enabling them to deliver location, spatial orientation (pitch, roll, yaw), behavior, and temporal-relationship information utilized by other GeoPoints, agents and users. GeoPoints are media rich and intelligent, and consist of raw data, multimedia, audio, video streams, text, sensor data, or any other digital information. Through positional and behavioral metadata, a GeoPoint becomes an enhanced LBS mediapoint that has a direct relationship to its physical location, as well as to other users and agents. The virtual Geopoint is viewed using an Augmented Reality (“AR”) client and a wearable computing system. A Geopoint Network can empower users to detach themselves from the desktop computer and dynamically move through a real world environment, interacting with GeoPoints and other users who are also seamlessly integrated into personal tasks and their own environments.
[0083] In another example embodiment, the system includes a connectivity manager and database server cluster responsible for data storage access, retrieval and complex data mining. The desktop, immersive, and mobile clients are connected via a high-speed network, such as a wired or wireless network, to the Internet. While the server network cluster is based on Standardized Commercial Off the Shelf (SCOTS) equipment, the client platforms, in various embodiments, are custom hardware and software configured specifically to targeted applications and include technologies such as Organic Light Emitting Diodes (OLED) display headsets, hybrid positioning systems, mesh technologies, and wearable computing devices (Wave Report, 2001; Kodak, Inc., 2003). The network is designed to provide several key functions to increase data management and flow and enhanced positioning information. Extended enhancements, according to another embodiment, include a versioning database for non-destructive editing of information, archiving, and media streaming. The network module can include LAN/WAN connections to wireless network access points for data delivery and manage the integrated GPS, Differential GPS (DGPS), and DGPS-IP positional information to increase the accuracy of positional information delivery (Rupprecht, 2002).
[0084] FIG. 17 is schematic illustrating generally Client Connectivity Manager (“CCM”) 1730 . The CCM serves as the communication hub between mobile users and relevant GeoPoint data. The CCM monitors a mobile client position by continuously receiving the client's GPS-based location and accessing the GIS database to retrieve the relevant data. The CCM automatically retrieves GeoPoint data for each user and provides information corresponding to the prescribed users' preferences and enforces client data access privileges.
[0085] GPS and DGPS signal streams based on RCTM IN NMEA OUT strings are obtained using a GPS receiver board embedded into each clients' wearable, or otherwise mobile, computing device. The positional accuracy of the client device is increased though the use of Assisted GPS technologies (Djuknic and Richton, 2002). Differential signals are broadcast through the Internet TCP protocols using a Differential Internet GPS technology called DGPS-IP (Rupprecht, 2002). By implementing this system and using the 802.11x wireless system for trilateration positioning, accuracy approaching and surpassing sub-meter positional accuracy becomes possible. As users traverse a physical environment, their location is relayed to the CCM, which responds by transmitting GeoPoint data retrieved from the GIS database. The GIS serves the GeoPoints to the clients and provides a mechanism to store and retrieve associated GeoPoint data such as imagery, video, audio, text, blueprints, and floor plans, and performs complex analysis (Câmara and Raper, 1999). The GIS functionality allows users to access available current data, historical and time-critical data, and also undertake what-if simulations and event modeling. The real-time connectivity allows a user to have a persistent connection to all new data, events and other information being updated in the system in real-time. Thus if the situation changes in one part of the network then other users across the entire network are also immediately undated.
[0086] The delivery of ‘just-in-time’ knowledge through an assistive and adaptive client holds considerable potential for improved decision-making, management and improved communication and data flow. The GeoPoint Network client, in one embodiment, is a custom application written for 2D and 3D static and mobile devices. Static devices include desktop and immersive virtual reality clients (both Headset and CAVE like environments). Mobile devices include Personal Digital Assistants (PDAs), and portable and custom wearable computing systems. The devices use positioning systems including E911 cellular technologies (Eichelberger, 2002; Yoshida, 1999), GPS, Assisted GPS, DGPS-IP and sensing technologies including accelerometers and magnetometers. Network connectivity is managed through a hybrid mix of 802.11x, LAN, and cellular 3G services. A custom peripheral can also be provided to manage and monitor network connections and supply the user with a consistent, best-available, “Quality of Service”. Machine Vision is used by the client to provide positional information, virtual user interfaces such as a gesture mouse and virtual keyboard, along with face recognition and tracking, and object recognition.
[0087] Building upon emerging Mesh Network technologies, according to one example embodiment, the system of the present subject matter creates a Mesh-Flocking system. By using ad-hoc mesh network data sharing, mobile users query a spatially close ‘knowledge neighbor’ for information relevant to their current query. This expedites and enhances the use of GeoPoint information by applying the local knowledge of an environment from other ‘experienced’ users to new users, thereby obviating the need for querying the remote database each time a request is made for data (Mobile Mesh, 2000; SearchNetworking.com, 2003).
[0088] In addition, each client receives GPS and sensing positioning information from the other nearby users to form a dynamic Flocking Constellation system. This system is an integration of artificial life ‘Flocking’ (Dolan, 2003; Reynolds, 2001), sensor technologies, and GPS. In the event that the GPS satellites become unavailable, clients can compute a synthetic position by combining trilateration techniques to the wireless infrastructure formed by the 802.11x ‘ad-hoc’ network among clients within the allowed range of wireless technologies.
[0089] In yet another embodiment, requests for GeoPoint data are parsed through the CCM to the enterprise GIS. The data query and search is optimized based on the client's location information and data is cached in readiness for client calls. The GIS database is based on Oracle Spatial and spatial information is retrieved using ESRI's Arc Spatial Data Engine (“ArcSDE”). Calls to the database for multimedia information are made using Oracle C++ Call Interface (“OCCI”), or other database API relevant to the particular embodiment. A comprehensive range of geographical and multimedia information can thus be made available to the client, along with the ability for users to establish their own GeoPoints and populate them with personal information. GIS functionality extends beyond data search and retrieval to include simulation and modeling capability (Raper, 2000). Thus requests to identify an optimal route from one GeoPoint to the next can be made to the GIS and a network route returned to the nearest GeoPoint. The exploitation of complex data mining between heterogeneous databases and real-time event modeling and simulation can draw heavily upon the advanced functionality of the GIS (Chrisman, 2001; Clarke, 2002; DeMers, 1999; Longley et al., 1999; Zeiler, 1999).
[0090] FIG. 18 is schematic illustrating a GeoPoint system architecture according to an embodiment. In this embodiment there is provided a hosting network for position acquisition, managing user requests, and serving GeoPoint data and media objects from the database server. The backend cluster network infrastructure is built, for example, on Gigabit connectivity, an Oracle Spatial database server, the Client Connectivity Manager server and a DGPS-IP positioning server. Mobile clients access the network through Wireless Access Points and 3G Cellular.
[0091] According to another example embodiment, a set of communication tools based on existing TCP and UDP protocols are provided and developed from C++ to support client/server interaction. The CCM is composed of a Communications Manager, an Administrative Manager, and a User Preferences Manager. The Communications Manager handles network and delivery protocols, supports multi-user activity, and request information from the database. The User Preferences Manager monitors user preferences and customizes user requests for data based on GeoPoints within the Client's awareness buffer. The Administrative Manager tracks permissible user data requests. The CCM is also responsible for handling client position, client data requests from remote servers, client login authentication, data encryption when transmitting between the mobile client and the CCM server, and updates the client-side GeoPoint display. Some embodiments further include an API for the client-side applications that provides client side applications connectivity to the CCM server.
[0092] The CCM continuously monitors the client location and performs spatially targeted constrained data requests to the database server. The enterprise GIS database is built on Oracle Spatial, accessed though ArcSDE and ESRI's object-relational Geodatabase (Zeiler, 1999). Both spatial and multimedia data are stored as objects. Spatial search and query functions are passed from the client through the CCM to the GIS. Using the location information of the client, data for the nearest available relevant GeoPoints are retrieved from the database and routed directly to the requesting client or routed through the CCM. Each GeoPoint is spatially recorded based on 8DOF (latitude, longitude, altitude, pitch, roll, yaw, direction, speed) and this positional accuracy enables GeoPoints to be differentiated and displayed in 3D coordinate space. The database is, according to one example embodiment, an Oracle Spatial running on Linux Advanced Server and linked to ESRI's ArcObjects (ESRI, 1999). The CCM provides client access to the media object attached to the GeoPoints and stored in the Oracle database. Access to this information is performed via OCCI database API for direct retrieval of non-GIS data. For GIS analysis, the CCM provides GeoPoint data access for GIS analysis via ArcSDE.
[0093] The complete mobile application combines accurate positioning, augmented reality, wireless networking, speech recognition, and machine vision modules ( FIG. 19 ). Users will, in one embodiment, experience the GeoPoint Network via a 3D augmented reality capable of displaying 3D objects overlaid on the physical environment and delivered through a next generation OLED augmented vision transparent headset or by using a mobile client screen as a virtual window. The mobile client application provides user interaction with the GeoPoints and other users and is responsible for establishing a network connection with the database via the CCM through which the Client's position is sent and relevant GeoPoint data is returned. Peer-to-Peer communication is also enhanced through audio, video, and text messaging services.
[0094] The mobile client user interface is achieved, in one embodiment, via machine vision, speech recognition, and speech synthesis. A ‘Gesture Mouse’ provides selection, modification, add, and delete capability through hand gestures (Machine Vision Group, 2003; Shamaie and Sutherland, 2001). Speech recognition and speech synthesis complement the Gesture Mouse with a vocal command capability as well as the ability to receive auditory feedback from the mobile client.
[0095] Accurate outdoor positioning is achieved through a combination of GPS, Differential GPS, and DGPS-IP. Indoor positioning is accomplished by computing an offset from a known location using a combination of magnetometers, gyroscopes, accelerometers, and Wireless Access Point trilateration. Both indoor and outdoor services are augmented using the Assisted GPS and the Mesh-Flock technology integrated with custom inertia position sensors for greater 8DOF accuracy.
[0096] According to one embodiment, a mobile client is provided for the Windows XP operating system running on a laptop computer equipped with a 3D accelerator graphics chip. In some embodiments, the mobile client is developed primarily in Java and Java 3D with some subcomponents developed in C with a JNI wrapper. Components are, in one embodiment, implemented in C and C++ to improve runtime performance. In order to utilize the advanced computing power of handheld devices, mobile client development can include a 2D planar version of the mobile client application to provide speech recognition, spatialized audio, and synthesized speech. In some embodiments, using the Pocket PC handheld platform, 3D graphic and augmented reality are delivered by a headset connected to a PocketPC or other similar personal digital assistant, mobile phone, or other mobile computing device. Such devices can enable sight-impaired users to use auditory GeoPoints as a tool of wayfinding and information retrieval.
[0097] The use of machine vision can augment the client application through an adaptive interface. A Gesture Mouse user interface recognizes hand gestures for performing advanced interaction tasks with the GeoPoints Network. The Gesture Mouse system is heuristic and adaptive and adjusts to the user's interaction style to minimize user learning and utilization. In addition the Gesture Mouse is capable of distinguishing the user's hand from background noise to minimize erroneous tracking. Advanced uses of the machine vision module include multiple face recognition and tracking, and text, object and environment recognition.
[0098] An immersive desktop version of the GeoPoint Editor provides interactive tools for creating and editing GeoPoints as well as complex environment building tools for the GeoPoint Network. The GeoPoint Editor provides a panoptic view of the overall environment and enables a user to create, modify, and delete GeoPoints, simulations and schemas by interacting with the virtual space. The GeoPoint Editor user is also able to manage and monitor mobile clients, interact directly with users through various communication tools, and provide advanced system administration functions. The editor is a module of the command console featuring extended GIS and management functionality for custom, mission-critical applications.
[0099] By linking to user-interface modules such as the Gesture Mouse, speech recognition, and speech synthesis; the Geopoint Editor enables users to freely interact with the Geopoint Network in virtual space through the immersive technology of a CAVE-style MultiWall (WVEL, 2003) virtual reality system developed at West Virginia University. The MultiWall virtual reality system is composed of an immersive wrap-around display provided by an 8′ rear-projected cube within which the user stands and interacts with the 3D virtual objects. Motion-tracking monitors user head location for proper perspective rendering and a module incorporate the Gesture Mouse to create, modify, and delete GeoPoints and drive the user interface. In some embodiments, the mobile client includes a scaled-down version of this editor for in-the-field interaction and control.
[0100] According to another example embodiment, a Flocking Constellation of mobile clients share network bandwidth and data, and act as a constellation of synthetic positional satellites to compute position based on telemetry. To achieve a shared, distributed mobile network, clients join ad-hoc networks of spatially close mobile clients via ad-hoc wireless networks to enable the sharing of network bandwidth and data. When a user requests information regarding a specific GeoPoint, the mobile client polls the other mobile clients in the ad-hoc network using in a ‘Go Fish’ scenario. If another user in the ad-hoc network has the relevant file, then it can be transferred to the requesting party via the same ad-hoc network. If no other user in the party has the requested data, then the clients can spawn multiple requests through a 3G Cellular network, or other suitable network type, to download portions of the data from a remote server. These downloaded segments are then combined locally by the requesting client and shared with other clients via the ad-hoc wireless network. In this way scarce client-server bandwidth is maximized.
[0101] Similarly, when a client seeks to upload GeoPoint information to the remote server, bandwidth is maximized by segmenting the data file into smaller portions that are dispersed to other users in the ad-hoc wireless network. These network members can then upload the data to the remote server through the 3G Cellular network where the segments are reassembled into a single file by the CCM. In this way the system reduces network transmission time.
[0102] The Flocking Constellation also provides a mechanism for establishing client position when the client is part of an ad-hoc network. As mobile clients traverse the physical environment, they act as ‘pseudo-satellites’ (synthetic GPS satellites) and transmit a GPS NMEA string to other mobile clients in the same ad-hoc network. The synthesized NMEA string is used to enhance a client's positional information as measured by GPS or other location sensors. The NMEA strings are then transmitted via the ad-hoc wireless network to the client and positions are established. If the GPS signal to a client is interrupted, other mobile clients can either continue to act as an ad-hoc network by receiving and transmitting their own positional information to the off-line client or may adjust their last known position based upon movement sensors.
[0103] In the foregoing Detailed Description, various features are grouped together in a single embodiment to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.
[0104] It will be readily understood to those skilled in the art that various other changes in the details, material, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this invention may be made without departing from the principles and scope of the invention as expressed in the subjoined claims.
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Systems, methods, and software for storage and distribution of real estate related data. Some embodiments include a database of data representing three-dimensional topographic views of geographic areas and a computer system adapted to present a topographic view of a geographic area based on a query by a user for information related to a listing of a property for sale or lease. In some embodiments, properties for sale or lease are plotted and identified within a three-dimensional topographic view providing the searcher a neighborhood view of the area of interest. Users can move around the three-dimensional topographic view as if they are flying overhead.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ophthalmic optical apparatus for observing and treating an eye, and more particularly to an ophthalmic optical apparatus having an alignment optical system for treating the eye.
2. Related Background Art
For a series of ophthalmic diseases including, inter alia, retina disease, a high density laser radiation or a so-called photo-coagulation laser is used to treat a diseased part and it is irradiated to the diseased part as a light spot. An irradiation output, an irradiation time and a spot size of the photo-coagulation laser are varied depending on a photo-coagulation operation to a particular diseased part. It is very important to focus the photo-coagulation laser to the diseased part, and to this end a proper alignment system is required. In a prior art alignment system, an alignment beam to be used for the alignment is split into two or more light beams which are collected and combined to attain exact focusing.
For example, in an ophthalmic optical apparatus (laser photo-coagulation apparatus) for observation and treatment which uses a laser, disclosed in U.S. Pat. No. 4,499,897, particularly in FIG. 5 thereof, an alignment laser beam 22 which is a visible ray generated by a laser oscillator 21 in the laser photo-coagulation apparatus 20 is split into two parallel light beams 22a and 22b by a pair of semi-transmissive prisms (beam splitter) 23, and those light beams pass through a first beam splitter (dichroic mirror) 24, are reflected by a ring-shaped outer periphery of a second beam splitter (dichroic mirror) 25 and directed to an object (an eye of a patient), not shown, through a focusing lens 26 so that they are focused on the object plane.
In this case, an in-focus state is attained at a point where the two light beams 22a and 22b coincide. When they are focused on the object plane, one spot pattern h is formed, and when they are not focused, two spot patterns g and i are formed.
On the other hand, a photo-coagulation light 29 for treatment which is generated by another laser oscillator 28 passes through a beam expander 30 so that it is expanded to a light beam having a diameter which is slightly smaller than a gap between the two alignment light beams 22a and 22b. The expanded photo-coagulation light is reflected by the first beam splitter (dichroic mirror) 24, follows the same light path as that of the alignment laser beam 22, is further reflected by the second beam splitter 25 and is directed to the object through the focusing lens 26 so that it is focused at the coincident point of the two beams 22a and 22b of the alignment laser beams 22, that is, at the same point as the point on the object plane at which the spot pattern h is formed.
In the laser photo-coagulation apparatus 20, the prism 23 is rotated so that the two light beams 22a and 22b are rotated around an optical axis of the photo-coagulation light 29. When the photo-coagulation light 29 is generated by the laser oscillator 28 after the in-focus state has been confirmed, the photo-coagulation light 29 follows the same light path as that of the alignment laser beam 22 and it is focused at the same point as the point on the object plane at which the spot pattern h of the alignment laser beam 22 is formed in the in-focus state so that the diseased part is treated.
In the prior art ophthalmic optical apparatus (laser photo-coagulation apparatus) for observation and treatment, since the two alignment light beams 22a and 22b which go along the outer periphery of the photo-coagulation light 29 are rotated around the optical axis of the photo-coagulation light 29, the construction is complex, a relatively long time is required for the alignment, the process to generate the photo-coagulation light 29 is complex and a long time is required for the treatment.
U.S. Pat. No. 4,917,486 discloses a laser photo-coagulation apparatus in which, instead of rotating the two alignment light beams, a mask having four apertures centered at an optical axis and arranged at an angular pitch of 90° is provided on an alignment light path of a collimated light beam, the four collimated light beams transmitted through the apertures of the mask are used as the alignment light beams which go along the outer periphery of the treatment light beam, and the in-focus state on the object plane is determined by the coincidence state of the four spot patterns formed by the four light beams.
However, in the laser photo-coagulation apparatus disclosed in U.S. Pat. No. 4,917,486, only those portions of the light generated by the alignment light source which are transmitted through the four apertures formed in the mask can be used as the alignment light beams and hence energy is wasted.
In the alignment system of the prior art laser photo-coagulation apparatus, the light beam is split into two or four parallel alignment light beams by the prism and they form the predetermined spot pattern at the in-focus state to permit the detection of the in-focus state. However, the position precision of the prism is hard to attain. Further, the entire construction of the optical system is complex and the prism cost is expensive.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ophthalmic optical apparatus which solves the above problems, attains exact focusing with a very simple alignment optical system, can confirm status of a light path through which a treatment light beam passes and attains the alignment rapidly and easily.
In order to achieve the above object, the ophthalmic optical apparatus having the alignment optical system in accordance with the present invention comprises means for generating a treatment laser light beam; means for generating an alignment light beam having a different wavelength than that of the treatment light beam; a focusing optical system for focusing the treatment light beam and the alignment light beam onto an object plane of an eye to be treated; and cone lens means having two conical planes for expanding the alignment light beam to a collimated light beam having a ring-shaped cross section along a periphery of the treatment light beam. The cone lens means includes a first conical plane arranged on the alignment optical axis for refracting the alignment light beam and expanding the same to a conical light beam centered on the optical axis, and a second conical plane for refracting the conical light beam, forming the same into a ring-shaped collimated light beam parallel to the optical axis and directing the same to said focusing optical system. Thus, the alignment light beam is formed into a small light spot pattern in an in-focus state and into a ring-shaped light pattern centered on the optical axis in a defocus state.
It is preferable that the cone lens means can vary a distance between the two conical planes in order to vary a ring diameter of the ring-shaped collimated light beam.
It is further preferable to obliquely arrange a reflection mirror on an alignment optical axis inside the ring-shaped collimated light beam and direct the treatment laser beam to the focusing optical system through the reflection mirror.
In the ophthalmic optical apparatus of the present invention thus constructed, the exact focusing is attained, the status of the light path through which the treatment light beam passes can be confirmed, and the alignment is made rapidly and with ease.
Other objects, features and advantages of the present invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic construction of an optical system and a sectional view of a light path in one embodiment of the present invention,
FIG. 2 shows a schematic construction of an optical system and a sectional view of a light path in another embodiment of the present invention.
FIGS. 3A to 3E show various cone lens devices used in the ophthalmic optical apparatus of the present invention and light paths thereof,
FIG. 3F shows a sectional view of a ring-shaped collimated light beam formed by the cone lens device of FIG. 2,
FIGS. 4A and 4B show cone lenses each having two planes thereof formed conical and light paths thereof, and
FIG. 5 shows a sectional view of a schematic construction of a prior art photo-coagulation apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the present invention is now explained in detail with reference to the accompanying drawings.
FIG. 1 shows a schematic construction of an optical system having an alignment optical system with a cone lens in an embodiment of the photo-coagulation apparatus of the present invention. In FIG. 1, an alignment beam 2 emitted from an alignment laser oscillator 1 is expanded by a beam expander 3 to a light beam having a circular cross-section of a predetermined diameter, and it is further expanded to a ring-shaped collimated light beam by a first cone lens 4A and a second cone lens 4B arranged on an optical axis and then it is directed to a focusing lens 5. The first cone lens 4A is a flat-convex cone lens having a conical convex plane faced to the light source. The alignment light beam directed to the first cone lens 4A is refracted by the conical convex plane of the first cone lens 4A and expanded to a conical light beam. The second cone lens 4B is a flat-convex cone lens having a conical convex plane faced to the focusing lens 5. The alignment light beam directed to the second cone lens 4B is refracted by the conical convex plane of the second cone lens 4B and formed into a ring-shaped collimated light beam 2R.
The ring-shaped collimated light beam 2R is focused by the focusing lens 5 to a plane of an object (not shown) which is to be ophthalmically treated. In an in-focus state, it is a point on a focal plane of the focusing lens 5 so that a small and bright light spot pattern b is formed on the object plane. In an out-of-focus state, a ring-shaped light pattern a or c is formed on the object plane and the diameter of the ring varies with the amount of defocusing accordingly, it is a point in the in-focus state and the brightness of the spot abruptly increases. This facilitates the detection of the in-focus state.
On the other hand, a photo-coagulation light 7 for treatment having a different waveform than that of the alignment light 2, which is emitted by a treatment laser oscillator 6 passes through a beam expander 8 and is expanded to a collimated light beam having a predetermined cross-section diameter. It is reflected by a mirror 9 obliquely arranged on an alignment optical axis inside of the alignment ring-shaped collimated light beam 2R, and then it follows the same light path as that of the alignment light beam and is directed to the focusing lens 5. In this case, a main optical axis of the photo-coagulation light coincides with the alignment optical axis which passes through the focusing lens 5. The photo-coagulation light directed to the focusing lens 5 is focused by the focusing lens 5 to the same position on the object plane as that at which the light spot b is formed by the alignment light beam so that the treatment photo-coagulation light spot is formed. Accordingly, in the treatment, the light spot pattern b by the alignment light beam is set at the predetermined position on the plane of object to be ophthalmically treated, and when the in-focus state is detected, the photo-coagulation light 7 is generated by the treatment laser oscilator 6.
The larger an incident angle δ to the object plane of the eye is, the higher is the precision of detection of the in-focus state. Accordingly, the larger the ring diameter of the ring-shaped collimated light beam of the alignment light is, the higher is the precision of the in-focus state detection. In the present embodiment, the two conical planes are formed by the two separate flat-convex cone lenses 4A and 4B and at least one of the cone lenses is movable along the optical axis to allow the adjustment of the distance between the two conical planes. Accordingly, by changing the distance between the cone lenses 4A and 4B, the ring diameter of the ring-shaped colliminated light beam may be increased and the precision of the detection of the in-focus state is enhanced. Since the ring-shaped light pattern abruptly changes the bright light spot, the detection of the in-focus state is facilitated.
In the present embodiment, since the treatment photo-coagulation light and the alignment light are directed to the focusing lens 5 through the common optical axis, if the numerical apertures of the alignment light and the photo-coagulation light are substantially equal, the spot size by the alignment light in the in-focus state and the spot size of the photo-coagulation light are substantially equal. Accordingly, the treatment position on the object plane and the size thereof can be estimated at the time of alignment.
FIG. 2 shows a schematic structure of an optical system in another embodiment of the present invention which has an alignment optical system including cone lenses. It is basically identical to the embodiment of FIG. 1 except a construction of a mirror which directs the photo-coagulation light to the focusing lens and the addition of an observation optical system, and the like elements are designated by the like numerals and the detailed explanation thereof is omitted.
In FIG. 2, the treatment photo-coagulation light 7 emitted by the treatment laser oscillator 6 is expanded by the beam expander 8 to a light beam having a predetermined cross-section diameter. The expanded photo-coagulation light is reflected by a dichroic mirror 9D obliquely arranged on the alignment optical axis so that it crosses an alignment ring-shaped collimated light beam 2R, and then it follows the same light path as that of the alignment light beam and is directed to the focusing lens 5. The dichroic mirror 9D exhibits a maximum reflection factor and a minimum transmission to the wavelength of the photo-coagulation light 7, and exhibits a maximum transmission and a minimum reflection factor to the wavelength of the alignment light 2. A mirror 10 is obliquely arranged on the alignment optical axis between the second cone lens 4B and the dichroic mirror 9D inside of the alignment ring-shaped collimated light beam 2R. The reflected light of the alignment light which is reflected by the object plane of the eye and transmitted through the center portion of the dichroic mirror 9D is directed to an observation optical system 11 by the mirror 10.
In the embodiment of the present invention shown in FIG. 2, the reflected light of the photo-coagulation light which is reflected by the object plane of the eye and goes backward along the optical axis is prevented by the dichroic mirror 9D from being directed to the observation optical system 11. Accordingly, the eye of the observer is protected from the photo-coagulation light. On the other hand, the alignment light 2R which is formed into the ring-shaped collimated light beam by the second cone lens 4B passes through the periphery of the dichroic mirror 9D and then it is focused by the focusing lens 5 so that a light spot b or a ring-shaped light pattern c is formed on the object plane of the eye. The reflected light of the alignment light reflected by the object plane goes along the optical axis, passes through the focusing lens 5, passes through the center portion of the dichroic mirror 9D and is directed to the observation optical system 11 through the mirror 10. Thus, the light spot pattern b or the ring-shaped pattern a or b can be observed. If a portion of the light path of the photo-coagulation light is blocked by an iris of the eye to be treated, a portion of the ring-shaped pattern observed is dropped. Accordingly, the treatment area of the eye can be recognized by the drop of the pattern. Practically, the dichroic mirror 9D may be a half-mirror. In this case, however, a laser beam protection filter is needed for the observation system.
Like in the embodiment of FIG. 1, the alignment light and the photo-coagulation light may have the same numerical aperture so that the spot size by the alignment light in the in-focus state is equal to the spot size of the photo-coagulation. Accordingly, by observing the spot size through the observation optical system 11 at the time of alignment, the treatment portion on the object plane and the size thereof can be exactly estimated. The ring diameter of the ring-shaped collimated light beam may be increased by changing the distance between the cone lenses 4A and 4B so that the precision of the detection of the in-focus state is enhanced.
The alignment (focusing operation) along the optical axis may be automated by arranging a photo-sensing device such as a CCD in parallel to the observation optical system 11.
In the above embodiments, an optical system for rendering a refractive power of the eye to zero is additionally arranged on the light path between the eye to be treated and the focusing lens 5.
In the above embodiments, the cone lens means comprising the two flat-convex cone lenses Aa and Ba as shown in FIG. 3A is used to form the ring-shaped collimated light beam as shown in FIG. 3F, although the cone lens means may be one of various combinations such as two flat-convex cone lens or a flat-concave cone lens and a flat convex cone lens as shown in FIGS. 3B and 3C. In FIGS. 3B and 3C, the first cone lens is a flat-concave cone lens Ab or Ac, and the second cone lens is a flat-convex cone lens Bb or Bc. In FIG. 3D, conical planes of two flat-convex cone lenses Ad and Bd are oriented in the same direction, and in FIG. 3E, conical planes of two flat-convex cone lenses Ae and Be face each other. As shown in FIGS. 4A and 4B, the cone lens means may be a bi-convex cone lens ABa having two conical planes or a meniscas cone lens ABb having a concave plane faced to a light source. When the bi-convex cone lens ABa or the meniscas cone lens ABb is used, it can be readily arranged on the alignment optical axis but the ring diameter of the ring-shaped collimated light beam is preset and not variable.
In accordance with the embodiment of the present invention, the exact focusing is attained with the simple alignment optical system having two conical planes and the light path of the treatment photo-coagulation light is secured. Further, since the distance between the two conical planes is variable, the precision of the detection of the in-focus state is enhanced.
When the present invention is applied to the photo-coagulation system as it is in the embodiment, the alignment light and the photo-coagulation light may have the same numerical aperture so that the size of the treatment point can be estimated from the spot size of the alignment light.
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An ophthalmic optical apparatus having an alignment optical system comprises two conical optical elements for forming an alignment light beam into a ring-shaped collimated light beam centered on an optical axis and directing it to a focusing optical system, an in-focus state is determined based on a light pattern formed by the focusing optical system from the ring-shaped collimated light beam on an object plane.
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